Flaky mesoporous particles, and method for producing the same

ABSTRACT

Provided is a mesoporous particle having a flaky shape, having a single-layer structure, having a thickness of 0.1 μm to 3 μm, and having an average pore diameter of 10 nm or more. The mesoporous particle can be obtained by a production method including: feeding a metal oxide sol having a pH of 7 or higher and containing metal oxide colloidal particles as dispersoids and water as a dispersion medium, into a liquid containing a water-miscible solvent having a relative permittivity of 30 or lower (protic solvent) or of 40 or lower (aprotic solvent) at 20° C., and thereby forming a flaky aggregate of the metal oxide colloidal particles in the liquid; and subjecting the aggregate to treatment such as drying and heating, and thereby converting the aggregate into a flaky particle that is insoluble in water.

TECHNICAL FIELD

The present invention relates to mesoporous particles as typified bymesoporous silica, and more particularly relates to flaky mesoporousparticles adapted to be blended with matrix materials.

BACKGROUND ART

Mesoporous silica is porous silica having mesopores with a diameterranging from 2 nm to 50 nm, and is expected to be used, for example, asa carrier for functional materials or as an adsorbent. Known methods forproducing the mesoporous silica include sol-gel methods using asurfactant micelle as a template, and methods forming a layeredpolysilicate as an intermediate.

Typical examples of silica-based particles currently mass-producedinclude glass flakes (scale-like pieces of glass). The glass flakes areused by being blended with matrix materials such as resin molded bodiesand cosmetics. Flaky particles have a larger surface area than sphericalparticles. In addition, when a thin coating film is formed by acomposition for application blended with flaky particles, the flakyparticles are oriented in the coating film in such a manner that theprincipal surfaces of the flaky particles are parallel to the surface ofthe coating film, and a large proportion of the base material to whichthe coating film has been applied is coated with the distributed flakyparticles. For these reasons, the flaky shape of particles is desirablein order to impart desired functions to matrix materials.

However, it has not been reported thus far that flaky mesoporous silicahas been obtained which has mesopores suitable for treatments such asadsorption and decomposition of macromolecules such as proteins, andwhich is adapted to be blended with matrix materials.

The shape of mesoporous silica obtained by conventional sol-gel methodsusing a surfactant micelle as a template has been limited to a rodshape. In response, Patent Literature 1 discloses that sheet-shapedmesoporous silica can be obtained by using a surfactant that can form aribbon phase or a nematic phase. However, the thickness of thesheet-shaped mesoporous silica obtained by this method is only less than50 nm (claim 2 of Patent Literature 1). Such a thin sheet material iseasily deformed, and is thus difficult to blend with matrix materialswithout any change in the shape.

In addition, in multi-layer mesoporous silica obtained by methodsforming a layered polysilicate as an intermediate, pore channels extendalong interlayer portions of the multi-layer structure, and therefore,surfaces that allow access to the mesopores are limited to only surfaceson which the interlayer portions are exposed. Accordingly, in the caseof mesoporous silica having a structure composed of tabular crystalslayered on each other, the mesopores cannot be accessed from the widestprincipal surface of the mesoporous silica. This makes it more likelythat the exertion of functions via the mesopores is restricted. Also inview of mechanical strength, a multi-layer body has a problem in thatpart of the layers is likely to be separated by a stress applied whenthe multi-layer body is blended with a matrix material or when thematrix material blended with the multi-layer body is molded. Themulti-layer structure having pore channels including mesopores andformed along the interlayer portions is not suitable as a basicstructure of flaky mesoporous silica to be blended with matrixmaterials.

CITATION LIST Patent Literature

-   Patent Literature 1: JP 2007-176783 A

SUMMARY OF INVENTION Technical Problem

The present invention aims to provide a flaky mesoporous particle thathas mesopores suitable for treatments such as adsorption anddecomposition of macromolecules such as proteins, and that is adapted tobe blended with matrix materials.

Solution to Problem

The present invention provides a mesoporous particle having a flakyshape, having a single-layer structure, having a thickness of 0.1 μm to3 μm, and having an average pore diameter of 10 nm or more.

In another aspect, the present invention provides a suitable method forproducing the mesoporous particle of the present invention, and themethod includes the steps of: feeding a metal oxide sol having a pH of 7or higher and containing metal oxide colloidal particles as dispersoidsand water as a dispersion medium, into a liquid containing awater-miscible solvent that is a protic solvent having a relativepermittivity (dielectric constant) of 30 or lower at 20° C., or that isan aprotic solvent having a relative permittivity of 40 or lower at 20°C., and thereby forming a flaky aggregate of the metal oxide colloidalparticles in the liquid; and subjecting the flaky aggregate to at leastone treatment selected from drying, heating, and pressurization, toincrease a binding force between the metal oxide colloidal particlesconstituting the flaky aggregate, and thereby converting the flakyaggregate into a flaky particle that is insoluble in water.

Advantageous Effects of Invention

With the present invention, a mesoporous particle adapted to be blendedwith matrix materials can be provided. The mesoporous particle of thepresent invention has a flaky shape. Accordingly, the mesoporousparticle has a large surface area per unit volume, and is excellent forexertion of functions. In addition, the mesoporous particle of thepresent invention has a single-layer structure, and has a thickness of0.1 μm to 3 μm. Accordingly, the mesoporous particle is less likely tobe deformed or broken when blended with a matrix material, and isadapted to be blended with a thin molded body such as a coating film.Furthermore, the mesoporous particle of the present invention hasmesopores with an average pore diameter of 10 nm or more, and is thussuitable for treatments such as adsorption and decomposition ofmacromolecules such as proteins. In addition, with the production methodof the present invention, the mesoporous particle adapted to be blendedwith matrix materials can be efficiently produced without using asurfactant micelle as a template.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 shows flaky silica particles obtained from No. 3 (organicsolvent: 2-propanol, see Table 1) of Example 1, as observed with anoptical microscope.

FIG. 2 shows flaky silica particles obtained from No. 3 (organicsolvent: 2-propanol, see Table 1) of Example 1, as observed with ascanning electron microscope (SEM).

FIG. 3 shows spherical silica particles obtained using 2-phenoxyethanolas an organic solvent in Example 1, as observed with an opticalmicroscope.

FIG. 4 shows non-spherical silica particles obtained from No. 12(organic solvent: 1-octanol, see Table 1) of Example 1, as observed withan optical microscope.

FIG. 5 shows flaky, fibrous, and spherical silica particles obtainedfrom No. 61 (organic solvent: 2-butoxyethanol 70+2-phenoxyethanol 30,see Table 6) of Example 4, as observed with an optical microscope.

FIG. 6 shows flaky, fibrous, and spherical silica particles obtainedfrom No. 61 (organic solvent: 2-butoxyethanol 70+2-phenoxyethanol 30,see Table 6) of Example 4, as observed with a SEM.

FIG. 7 shows spherical silica particles obtained from No. 65 (organicsolvent: 2-butoxyethanol 30+2-phenoxyethanol 70, see Table 6) of Example4, as observed with an optical microscope.

FIG. 8 shows fibrous and flaky silica particles obtained from No. 77(organic solvent: 2-butoxyethanol 45.5+2-ethoxyethanol9.1+2-phenoxyethanol 45.5, see Table 7) of Example 4, as observed withan optical microscope.

FIG. 9 shows fibrous and spherical tin oxide particles obtained from No.203 (SnO₂ sol, organic solvent: 2-butoxyethanol 70+2-phenoxyethanol 30,see Table 20) of Example 5, as observed with an optical microscope.

FIG. 10 shows flaky silica particles obtained in Example 6 by addingglycerin to a silica sol and dropping the silica sol into 2-propanol, asobserved with an optical microscope.

FIG. 11 shows flaky silica particles obtained in Example 8 and includinginternally titanium oxide (titania) fine particles, as observed with aSEM.

FIG. 12 shows spectral transmittance curves for titania fineparticle-including silica particles obtained in Example 8, and for thesame amount of titania fine particles as included in the silicaparticles.

FIG. 13 is a diagram showing the relation between the titania fineparticle concentration and the light transmittance (wavelength: 300 nm)in a titania fine particles-including silica powder obtained in Example9 and having a particle weight concentration (PWC) of 0.1% by weight.

FIG. 14 shows flaky silica particles obtained from No. 223 (organicsolvent: 2-propanol, see Table 22) of Example 10 and includinginternally carbon black fine particles, as observed with an opticalmicroscope.

FIG. 15 shows thick fibrous silica particles obtained from No. 224(organic solvent: 2-propanol 60+2-ethyl-1-hexanol 40, see Table 22) ofExample 10 and including internally carbon black fine particles, asobserved with an optical microscope.

FIG. 16 is a perspective view of an example of a mesoporous particle ofthe present invention.

DESCRIPTION OF EMBODIMENTS

Hereinafter, embodiments of the present invention will be described withreference to the drawings. An example of a mesoporous particle 1 of thepresent invention is shown in FIG. 16. The particle 1 is a single-layerbody having a flaky outer shape. The flaky particle 1 has a pair ofprincipal surfaces 11 substantially parallel to each other, and thethickness of the particle 1 is defined by the distance between theprincipal surfaces 11. In the case of a particle having a multi-layerstructure, the side surfaces of the layers and the interlayer portionsare exposed on the side surface of the particle. However, a side surface12 of the single-layer particle 1 does not have such appearancecharacteristics.

In the present specification, the term “flaky” means the shape of aplate-like body whose principal surfaces can be regarded as flat orcurved surfaces and in which the ratio of the average diameter of eachprincipal surface to the thickness is 3 or more. In view of blending ofthe flaky particle with matrix materials, the appropriate thickness ofthe flaky particle is 0.1 μm to 3 μm, and the thickness is preferably0.2 μm to 2 μm. Assuming a circle having an area equal to the area ofthe principal surface of the flaky particle, the average diameter of theflaky particle corresponds to the diameter of the circle. The averagediameter is preferably 1 μm to 1 mm, more preferably 2 μm to 0.5 mm, andparticularly preferably 5 μm to 0.3 mm. The ratio of the maximumdiameter to the minimum diameter in the principal surface is preferably1 to 10, and more preferably 1 to 4. The ratio of the average diameterof the principal surface to the thickness is preferably 5 or more, andmore preferably 10 or more, and is, for example, 30 or less, andpreferably 20 or less. The definitions of the shapes other than theflaky shape (fibrous, spherical, and non-spherical shapes) will bedescribed later.

The particle 1 is a mesoporous body, and is provided with so-calledmesopores. The mesopores are pores having a diameter of 2 nm to 50 nm.The mesopores in the particle 1 have an average pore diameter of 10 nmor more, and can take in macromolecules such as proteins. The particle 1in the present embodiment is composed of metal oxide particlesaggregated in such a manner as to form mesopores between the particles.Therefore, the particle 1 has mesopores not only in the side surface 12but also in the principal surfaces 11. That is, all the surfaces havemesopores. The mesoporous particle 1 having such preferredcharacteristics can be obtained by the above-described method using ametal oxide sol, more specifically, by the production method of thepresent invention in which metal oxide colloidal particles areaggregated into a flake.

This method utilizes, as a particle formation mechanism, a phenomenon inwhich, in the course of interdiffusion between the metal oxide sol andthe solvent, the electrical repulsion between the metal oxide colloidalparticles decreases to cause aggregation of the colloidal particles. Inthis formation mechanism, the colloidal particles are aggregated in sucha manner as to form mesopores between the particles. Therefore, amesoporous particle can be obtained without using a template such as asurfactant micelle. Hereinafter, the production method of the presentinvention suitable for producing the mesoporous particle 1 will bedescribed. When the particle formation mechanism that forms the basis ofthe production method of the present invention is applied, a particlecan be obtained in the form of a fiber, a sphere, or the like bycontrolling the mode of aggregation of the colloidal particles.Accordingly, not only the conditions for obtaining a flaky particle, butalso the conditions for obtaining various shapes of particles aredescribed below.

First, the definitions of the terms will be described. An aggregateformed by aggregation of the metal oxide colloidal particles is solublein water before being suitably treated. For example, when the aggregateis put into water which is then stirred, the aggregate is dispersedagain in the form of metal oxide colloidal particles. However, if theaggregate is subjected to treatment, such as drying and heating, toincrease the binding force between the metal oxide colloidal particles,the aggregate becomes insoluble in water. In the present specification,an aggregate that has undergone insolubilization is referred to as a“particle”, and an aggregate that has not undergone insolubilization andis soluble in water is referred to as an “aggregate”. Therefore, forexample, a burned product (sintered product) obtained from an aggregateis categorized as a “particle”. Whether or not an aggregate is“insoluble in water” can be determined by whether or not the aggregateis dissolved in 20° C. water when the water is stirred by agenerally-used stirring means (e.g., a magnetic stirrer).

In the following description, the values of the “relative permittivity”and the “solubility in water” are values measured at 20° C., unlessotherwise specified. The “viscosity coefficient” mentioned later is alsobased on a value measured at 20° C. As is well known, the unit “g/100ml” of the solubility in water of a solvent indicates the upper limit ofthe amount of the solvent soluble in 100 ml of water. In addition,similar to the case of the solubility, whether or not a solvent ismiscible with water is determined at 20° C.

In the present specification, the terms used for describing the types ofsolvents are defined as below. A “protic solvent” is a solvent whosemolecular structure has a proton-donating functional group. Examples ofthe proton-donating functional group include carboxylic acid groups andalcoholic hydroxyl groups. An “aprotic solvent” is a solvent whosemolecular structure has no proton-donating functional group.

For a protic solvent, the term “low-permittivity” means that the proticsolvent has a relative permittivity of 30 or lower. For an aproticsolvent, the term “low-permittivity” means that the aprotic solvent hasa relative permittivity of 40 or lower. The term “high-permittivity”means that the relative permittivity is higher than 30 (protic solvent)or higher than 40 (aprotic solvent). The term “polar” means that thesolubility of a solvent in water is 0.05 g/100 ml or more, while theterm “non-polar” means that the solubility is less than 0.05 g/100 ml.The term “aqueous” means that a solvent is miscible with water, in otherwords, means that the solvent has an infinite solubility (∞) in waterand can be mixed with water at an arbitrary ratio. The term“non-aqueous” means that the solubility of a solvent in water has afinite value. Accordingly, an “aqueous” organic solvent means a “polar”organic solvent even when no particular mention is made.

A description will be given of the mechanism of formation of anaggregate of metal oxide colloidal particles in the particle formationmechanism on which the production method of the present invention isbased.

As is well known, colloidal particles repel each other due to theirelectric charges, and thus maintain a stable dispersion state in amedium. The lower the permittivity of the dispersion medium(liquid-phase medium in the present invention) present between thecolloidal particles is, the smaller the electrical repulsion actingbetween the colloidal particles is. The present invention utilizes aphenomenon in which colloidal particles are aggregated due to reductionin repulsion associated with decrease in permittivity.

When a metal oxide sol whose dispersion medium is water is fed into aliquid, the liquid phases interdiffuse at the interface between the soland the liquid having received the sol. In the case where the liquidcontains a solvent that can interdiffuse with water, and where therelative permittivity of the solvent is smaller than the relativepermittivity of water (about 80), the interdiffusion between the solventand water reduces the permittivity of the liquid-phase medium presentbetween the metal oxide colloidal particles, and accordingly reduces theelectrical repulsion between the colloidal particles. If the cohesiveforce derived from a universal attracting force acting between thecolloidal particles becomes larger than the repulsion as a result of thereduction in the repulsion, the colloidal particles are aggregated. Inthis case, the colloidal particles are aggregated in a region at whichthe solvent and water interdiffuse (hereinafter, the region may bereferred to as “interface”), and the aggregate of the colloidalparticles grows. When the weight of the aggregate exceeds a weight thatallows dispersion, the aggregate falls from the interface and settlesout.

Depending on the form of aggregation, a new interface is formed at thesite from which the aggregate has settled out. In this case, thecolloidal particles are further aggregated at the new interface, andsettle out. In this manner, aggregates are formed and settle out oneafter another.

In order to form aggregates of colloidal particles by the abovemechanism, a protic solvent having a relative permittivity of 30 orlower, or an aprotic solvent having a relative permittivity of 40 orlower, should be used. A solvent having a relative permittivity higherthan the above upper limit cannot provide sufficient reduction in therepulsion between the colloidal particles to cause aggregation of thecolloidal particles.

Examples in which a protic solvent is used are described below. When ametal oxide sol whose dispersion medium is water is dropped into ethanol(relative permittivity: 24) or into 2-ethoxyethanol (=ethylene glycolmonoethyl ether, relative permittivity: 30), aggregates of colloidalparticles are formed. By contrast, when the sol is dropped into methanol(relative permittivity: 33), into ethylene glycol (relativepermittivity: 39), or into propylene glycol (relative permittivity: 32),the colloidal particles maintain the dispersion state. Examples in whichan aprotic solvent is used are described below. When the metal oxide solis dropped into acetone (relative permittivity: 21) or into acetonitrile(relative permittivity: 38), aggregates of the colloidal particles areformed. By contrast, when the sol is dropped into dimethyl sulfoxide(relative permittivity: 49), the colloidal particles maintain thedispersion state.

The reason why the upper limit of the relative permittivity of aproticsolvents is higher than the upper limit of the relative permittivity ofprotic solvents is thought to lie in the fact that the higher therelative permittivity of a protic solvent is, the larger the number offree protons is, and thus the more likely the colloidal particles are tobe stabilized by electrical double layers.

A solvent having a sufficiently low relative permittivity but having anextremely low affinity for water cannot interdiffuse with water toreduce the repulsion between the colloidal particles. Accordingly, asolvent having a solubility in water of 0.05 g/100 ml or more should beused. For example, when a metal oxide sol whose dispersion medium iswater is dropped into 1-octanol (solubility in water: 0.054 g/100 ml),aggregates of the colloidal particles are formed. By contrast, when thesol is dropped into hexane (solubility in water: 0.001 g/100 ml) whichhas a sufficiently low relative permittivity of about 2 but which ishardly soluble in water, no aggregates of the colloidal particles areformed. Solvents that are hardly insoluble in water and categorized asnon-polar solvents in the present specification, cannot causeaggregation of colloidal particles even if the solvents have a polarfunctional group. Examples of such non-polar solvents include isopropylmyristate.

As will be described later, the shape of the resultant aggregates isinfluenced by the solubility in water of a solvent used. When a solventhaving a solubility in water of 2 g/100 ml or more is used, the tendencyfor the aggregates to take the form of spheres, fibers, or flakes isstrong, and the industrial utility of the aggregates or particlesobtained from the aggregates is increased. By contrast, when a solventhaving a solubility in water less than 2 g/100 ml, the aggregates arevery likely to take the form of non-spherical agglomerates which areless useful industrially. Therefore, in general, the solubility in waterof a solvent used is preferably 2 g/100 ml or more. In the case wherecolloidal particles should be aggregated into flakes as in theproduction method of the present invention, a solvent having asufficiently high solubility in water, that is, a (aqueous) solventmiscible with water, is suitably used. In an embodiment of the presentinvention, a metal oxide sol starts to be dropped into a liquid at leastpart of which is an aqueous low-permittivity organic solvent. Theproportion of the aqueous low-permittivity organic solvent in the liquidis preferably 50% by weight or more, and more preferably 80% by weightor more.

Generally, in an acidic metal oxide sol, the colloidal particles cannotcome close to each other due to the effect of hydration energy, and arein a stable state. Therefore, in the case of using an acidic metal oxidesol, aggregation of the colloidal particles is less likely to be causedby reduction in electrical repulsion associated with interdiffusion. Bycontrast, in an alkaline metal oxide sol, the influence of hydrationenergy is small, and the colloidal particles are stabilized byelectrical double layers formed on the surfaces of the colloidalparticles and represented by -MO-H⁺ and -MO-R⁺ (where M is a metalelement such as Si, Ti, and Zr, and R is an alkali metal element astypified by Na). Therefore, in the case of using an alkaline metal oxidesol, the repulsion between the colloidal particles can be sufficientlyreduced by interdiffusion between a low-permittivity polar solvent andwater, to cause aggregation of the colloidal particles. More precisely,the sol whose colloidal particles are aggregated by reduction in thepermittivity of the dispersion medium need not be an alkali, and it issufficient for the sol to have a pH of 7 or higher.

Hereinafter, a description will be given of embodiments of the steps ofthe production method for aggregating metal oxide particles so as toform mesopores, and obtaining mesoporous particles from the aggregates.

As is well known, a metal oxide sol can be prepared by hydrolyzing ametal alkoxide. Alternatively, a previously-preparedcommercially-available product may be used. In either case, a sol havinga pH of 7 or higher needs to be prepared. The pH of the sol may beselected as appropriate within a suitable range depending on, forexample, the type of the metal oxide. The pH is, for example, 7.5 orhigher, and is particularly preferably 8 to 12. For example, the metaloxide colloidal particles of the metal oxide sol are colloidal particlesof at least one selected from silicon oxide, titanium oxide, zirconiumoxide, aluminum oxide, tantalum oxide, niobium oxide, cerium oxide, andtin oxide.

As described above, the solvent that interdiffuses with water and thuscauses aggregation of the colloidal particles is a low-permittivitypolar solvent. Since the shape of the resultant particles depends on thetype of the low-permittivity polar solvent, the type of thelow-permittivity polar solvent should be selected in accordance with theshape of the particles to be formed. The liquid into which a sol is tobe fed such as by introducing droplets of the sol, may consist only of alow-permittivity polar solvent. Alternatively, the liquid may contain asolvent whose relative permittivity and/or solubility in water do notsatisfy the above conditions. As is clear from Examples described later,it is fully possible to obtain aggregates of colloidal particles evenwhen a sol is continuously fed into a liquid in which the proportion ofa low-permittivity polar solvent is about 20% by weight (in other words,even when the proportion of the solvent is decreased below 20% by weightas a result of weight increase associated with the feed of the sol).However, when the proportion of the low-permittivity polar solvent inthe liquid into which the sol is fed is low, the proportion of colloidalparticles that remain dispersed without being aggregated may increase,leading to reduction in yield. The proportion of the low-permittivitypolar solvent in the liquid into which the sol is fed is 15% by weightor more, preferably 20% by weight or more, and particularly preferably30% by weight or more, and may be 50% by weight or more. It should beunderstood that the liquid may contain two or more types oflow-permittivity polar solvents.

A low-permittivity polar solvent suitable for practical use is alow-permittivity polar organic solvent. The low-permittivity polarorganic solvent is preferably an organic solvent categorized as at leastone selected from an alcohol, an aldehyde, a carboxylic acid, acarboxylic acid ester, an ether, a ketone, an amine, an amide, anitrile, a heterocyclic compound, and a halogenated hydrocarbon. Forexample, 2-ethoxyethanol mentioned above is categorized as an alcoholand also as an ether. Typical examples of the low-permittivity polarorganic solvent are those described in EXAMPLES. However, there are manysolvents that allow aggregation of colloidal particles, and suchsolvents are not limited to the solvents described in EXAMPLES.

Feed of a metal oxide sol into a liquid is preferably carried out insuch a manner that the sol introduced is present in the form of dropletssurrounded by the liquid. For this purpose, the most reliable way is tointroduce the sol in the form of droplets, in other words, to drop thesol. In the case where the amount of a sol introduced per unit timeneeds to be increased from the standpoint of production efficiency, twoor more dropping devices may be used to drop the sol into a liquid. In apreferred embodiment of the present invention, a sol is dropped into aliquid held in a container from two or more dropping devices, preferablyin a concurrent manner.

Even when a sol is fed into a liquid from an introduction pipe such as atube, if a stress is applied to the fed sol such as by stirring theliquid, the fed sol can be dispersed in the liquid in the form ofdroplets. In this case, the inner diameter of the outlet of theintroduction pipe should be limited to 5 mm or less, preferably 2 mm orless, and is preferably limited within a range of, for example, 0.1 mmto 1 mm. In a preferred embodiment of the present invention, a sol isfed through an introduction pipe into a liquid while the liquid isstirred, and the sol is dispersed in the liquid in the form of droplets.

In some cases where the amount of a sol fed into a liquid is excessiverelative to the amount of the liquid, the colloidal particles are lesslikely to be aggregated, and the yield of aggregates is reduced.Therefore, the appropriate total amount of a sol fed into a liquid is ina range of 20% by weight or less, preferably 10% by weight or less, andmore preferably 5% by weight or less, relative to the amount of theliquid.

Feed of a metal oxide sol into a liquid containing a low-permittivitypolar solvent is preferably carried out while the liquid is stirred.This is because the stirring makes it easier for the sol to be dispersedin the form of droplets, and facilitates separation of aggregates of themetal oxide colloidal particles from the interface between water and thesolvent. In addition, when introduction of the sol is accompanied bystirring of the solvent, the time during which the droplets are keptsurrounded by the liquid phase is increased, compared to when thesolvent is not stirred. This leads to increase in the number of theresultant particles having the same shape. For example, the sol isintroduced in the form of droplets into the liquid held in a containerfrom above. Alternatively, for example, the sol is introduced into theliquid held in a container through an introduction pipe whose outlet isplaced in the liquid, and the sol is dispersed to form droplets. Ingeneral, the droplets settle out in the liquid to the bottom of thecontainer while causing formation of aggregates of colloidal particles.Aggregates are also formed from droplets having reached the bottom ofthe container. However, at the interface surrounding the droplets havingreached the bottom, the cycle of formation of an aggregate and formationof a new interface due to falling of the aggregate is less likely torepeatedly occur. In addition, there is a tendency that aggregatesformed from droplets being in contact with the bottom of the containerhave a large thickness. Accordingly, in some cases, bulked aggregatesare formed from droplets having reached the bottom even if the dropletscause formation of flaky aggregates before reaching the bottom.

Stirring of the liquid also exerts an influence on the shape of theaggregates. In order to obtain fibrous or flaky particles, aggregationof metal oxide colloidal particles should be facilitated. Accordingly,feed of the metal oxide sol into the liquid is preferably accompanied bystirring of the liquid, especially when a fibrous or flaky shape shouldbe obtained. The stirring of the liquid is preferably performed with acommonly-known stirring device such as a magnetic stirrer, and a stirrerequipped with a stirring blade and a shaft functioning as a rotationalaxis.

The size of droplets also has an influence on the shape and size of theparticles. In general, each droplet preferably has a size of 5 mg to1000 mg. If the droplets are too small, the size of aggregates islimited. Accordingly, each droplet present in the liquid preferably hasa size of 10 mg or more, especially when colloidal particles should beaggregated so as to obtain flaky or fibrous particles. However, if thedroplets are too large, the shapes of aggregates may vary widely.Therefore, each droplet preferably has a size of 500 mg or less. Eachdroplet particularly preferably has a size of 10 mg to 300 mg.

Introduction of droplets may be performed using a commonly-knowndropping device such as a dropper and a pipette. For mass production,droplets may be continuously introduced using various dispensers.Commercially-available droppers or pipettes are not suitable forformation of large droplets. Therefore, when a commercially-availabledropper or pipette is used, its tip may be processed as appropriate.Droplets may be continuously introduced using any of these droppingdevices, or may be introduced from a plurality of dropping devicesconcurrently.

Aggregates having been formed can be dissolved in water if theaggregates have not undergone any treatment. This is because the bindingstrength between the metal oxide colloidal particles constituting theaggregates is not sufficiently high. Accordingly, in order to make theaggregates insoluble in water and suitable for various uses, the bindingstrength between the metal oxide colloidal particles may be increased bysubjecting the aggregates to at least one treatment selected fromdrying, heating, and pressurization. The treatment allows the bindingbetween the metal oxide colloidal particles to proceed irreversibly,thereby converting the aggregates into particles insoluble in water.

Drying is convenient as a treatment for insolubilizing the aggregates.Drying causes xerogelation (hereinafter, simply referred to as“gelatinization”) of the aggregates, and thus makes the aggregatesinsoluble in water. In advance of the drying, the aggregates areseparated from the liquid containing the aggregates. Alternatively, theliquid containing the aggregates may be put into storage as it is, andthe separation and drying may be carried out when necessary. In thiscase, it is advantageous that the liquid containing the aggregates beput into storage after the content of the aggregates is increased bycarrying out a step of removing part of the liquid containing the formedaggregates in such a manner that the remaining liquid contains theaggregates. Also in the case where, for example, the aggregates areheat-treated, the treatment efficiency can be enhanced by previouslyincreasing the content of the aggregates in the liquid. When the sol isfed into the liquid held in a container, the aggregates having beenformed settle out to the bottom of the container to form a white slurry.If the liquid is removed from the upper portion of the container in sucha manner that the aggregates remain in the container, the liquid can beseparated from the aggregates remaining in the container. The removedliquid may be reused for aggregation of metal oxide colloidal particles.

The removed liquid may be reused as it is for aggregation of colloidalparticles. However, if the water content in the liquid is high,colloidal particles may be less prone to aggregation. Therefore, it isadvantageous that the liquid be reused after the water content in theliquid is reduced or, preferably, water is removed from the liquid, by acommonly-known solvent regeneration technique such as distillation,dehydration by a separation membrane, and dehydration by freezeconcentration.

The insolubilization of the aggregates can also be carried out byheating and/or pressurization. Specifically, the liquid containing theaggregates may be heated and/or pressurized as it is, or heating and/orpressurization may be performed after the liquid is replaced withanother solvent (a solvent for heat treatment), so as to allow thebinding between the metal oxide colloidal particles to proceedirreversibly.

In this case, the heating temperature is preferably 50° C. or higher,and more preferably 70° C. or higher, for example, 78° C. to 85° C. Theheating is carried out at a temperature lower than or equal to theboiling point of the liquid. Therefore, especially when the solventcontained in the liquid has a somewhat low boiling point of 50° C. orlower, it is preferable that the heating be carried out after the liquidis replaced with a solvent for heat treatment having a higher boilingpoint of, for example, 70° C. or higher. The heating time is notparticularly limited, and may be set as appropriate depending on theapplied temperature or the like. For example, the heating time is 0.1hours to 12 hours, and particularly 2 hours to 8 hours. When a liquidcontaining aggregates was heat-treated at 82° C. for 8 hours, theaggregates were converted into particles. The particles obtained afterthe treatment were able to maintain their shapes even when they were putinto water which was then stirred, whereas the aggregates before thetreatment were so weak that the aggregates were broken when they wereput into water which was then stirred.

The pressure in pressurization is preferably 0.11 MPa or higher, morepreferably 0.12 MPa or higher, and particularly preferably 0.13 MPa orhigher, for example, 0.12 MPa to 0.20 MPa. For example, thepressurization can be performed by putting a liquid containingaggregates in a container, and setting the pressure of an atmospherethat is in contact with the liquid at around the values indicated above.The pressurization time is not particularly limited, and may be set asappropriate depending on the applied pressure or the like. For example,the pressurization time is 0.2 hours to 10 hours, and particularly 1hour to 5 hours. In view of weakness of the aggregates, thepressurization is preferably performed at a static pressure. When aliquid containing aggregates and held in a chamber was subjected to apressure of 0.15 MPa for 3 hours, the aggregates were converted intoparticles. The particles obtained after the treatment were able tomaintain their shapes even when they were put into water which was thenstirred, whereas the aggregates before the treatment were so weak thatthe aggregates were broken when they were put into water which was thenstirred. The heating and pressurization may be carried outsimultaneously or sequentially.

Particles obtained through gelatinization of aggregates by drying andthrough the subsequent burning have excellent mechanical strength.However, particles containing a metal oxide are not necessarily requiredto have excellent mechanical strength for every kind of use. Dependingon the intended use, particles obtained by the heating and/or thepressurization described above may be used without being gelatinized.

In order to obtain metal oxide particles gelatinized by drying,aggregates need to be separated from a liquid containing the aggregates.It is advantageous that the separation step be carried out bysolid-liquid separation, and thus the formed aggregates be separatedfrom the liquid. The solid-liquid separation can be performed using acommonly-known technique such as filtration, centrifugation, anddecantation. The aggregates separated from the liquid by the separationstep may be put into storage as they are, or may be further subjected tothe subsequent washing step and then put into storage. As describedabove, the separated liquid can be reused for aggregation of metalcolloidal particles after the water content is reduced as necessary. Ina preferred embodiment, the production method of the present inventionfurther includes the step of reusing the liquid separated from theaggregates, or part of a liquid separated from the remaining liquid, asat least part of a liquid for aggregation of colloidal particles.

The separated aggregates are preferably washed in advance of drying, soas to wash away the liquid attached to the aggregates. In the case wherea solvent having a boiling point higher than 100° C. is used, it isrecommended that the washing step be carried out with a washing agenthaving a boiling point lower than that of the solvent. However, when theaggregates are washed with water, caution should be exercised becausethe aggregates may be dissolved. A low-permittivity polar organicsolvent, in particular, a low-permittivity polar organic solvent havinga low molecular weight and a boiling point lower than 100° C., astypified by ethanol and acetone, is suitable as the washing agent.

After the washing, the aggregates are dried. The conditions for thedrying step are not particularly limited, and the drying step may beperformed by natural drying (air drying at normal temperature). However,it is advantageous that the drying step be carried out in an atmospherehaving a temperature appropriate for the type of the liquid to beremoved. For example, the temperature is 40° C. to 250° C., andparticularly 50° C. to 200° C. The aggregates are gelatinized by thedrying, and thus become insoluble in water.

After the drying, the particles obtained by gelatinization are burned asnecessary. The burning can enhance the strength of the particles. Theburning is preferably carried out in an atmosphere having a temperatureof, for example, 300° C. to 1500° C., particularly 400° C. to 1200° C.That is, in a preferred embodiment, the production method of the presentinvention further includes the step of burning the particles at atemperature of 300° C. or higher. The burning step may be carried out incontinuation to the drying step described above. That is, for example,the aggregates may be dried during a temperature-increasing process forburning of particles, and the particles obtained by the drying may beburned without any interruption.

As described above, the shape of the particles to be formed isinfluenced by the type of a low-permittivity polar solvent. For example,an aqueous low-permittivity organic solvent is suitably used for formingflaky particles. In a preferred embodiment of the present invention, atleast part of the low-permittivity polar solvent used is an aqueouslow-permittivity organic solvent (hereinafter, may be referred to as“organic solvent A”), and at least part of the resultant particles areflaky particles. In this case, the proportion of the organic solvent Ain the low-permittivity polar organic solvent is preferably 50% byweight or more, more preferably 70% by weight or more, and particularlypreferably 90% by weight or more. The use of a solvent containing a highproportion of the organic solvent A allows substantially all (e.g., 95%by weight or more) of the resultant particles to be flaky particles.

Stirring of a liquid into which a metal oxide sol is fed is notessential for formation of flaky particles. However, if the liquid isstirred, an interface at which water and an organic solvent interdiffuseis extended, and colloidal particles are aggregated at the extendedinterface. Therefore, stirring of the liquid contributes to aggregationof the colloidal particles into flakes.

Spherical and fibrous mesoporous particles can also be obtained byapplying the particle formation mechanism employed in the productionmethod of the present invention, and by appropriately selecting asolvent. A non-aqueous low-permittivity polar organic solvent issuitably used for forming spherical particles. When at least part of thelow-permittivity polar solvent used is a non-aqueous low-permittivitypolar organic solvent (hereinafter, may be referred to as “organicsolvent B1”), at least part of the resultant particles are sphericalparticles. In this case, the proportion of the organic solvent B1 in thelow-permittivity organic solvent is preferably 50% by weight or more,more preferably 70% by weight or more, and particularly preferably 90%by weight or more. The use of a solvent containing a high proportion ofthe organic solvent B1 allows substantially all (e.g., 95% by weight ormore) of the resultant particles to be spherical particles. It isadvantageous that the organic solvent B1 used be a solvent having asolubility in water of 50 g/100 ml or less, particularly 30 g/100 ml orless, more particularly less than 10 g/100 ml, for example, 2 g/100 mlor more and less than 10 g/100 ml. With this method, it is also possibleto mass-produce spherical particles having a particle diameter of 1 μmor more, particularly 5 μm or more, more particularly more than 10 μm,and, in some cases, more than 15 μm.

A liquid containing two or more organic solvents is suitably used forproducing fibrous particles. When at least part of the low-permittivitypolar solvent is an aqueous low-permittivity polar organic solvent(organic solvent A), and the liquid into which a metal oxide sol is fedcontains an organic solvent immiscible with water (hereinafter, may bereferred to as “organic solvent B”), at least part of the resultantparticles are fibrous particles. The organic solvent B may be anon-aqueous low-permittivity polar organic solvent (organic solvent B1)or may be another non-aqueous organic solvent, for example, anon-aqueous low-permittivity non-polar organic solvent (hereinafter, maybe referred to as “organic solvent B2”) such as hexane. That is, in thecase where fibrous particles are to be produced, the liquid to which thesol is fed may contain the organic solvent A and the organic solvent B1as low-permittivity polar solvents, or may contain the organic solvent Aas a low-permittivity polar solvent and the organic solvent B2 which isnot a low-permittivity polar solvent. In addition, in order to obtainfibrous particles, a mixed solvent composed of the organic solvent A,and the organic solvent B1 and/or the organic solvent B2, may be used asthe liquid into which the metal oxide sol is fed. In this case, it isadvantageous that the organic solvent B1 used be a solvent having asolubility in water of 50 g/100 ml or less, particularly 30 g/100 ml orless.

In many cases, fibrous particles are formed together with blockyparticles such as spherical particles, and/or together with flakyparticles. In order to increase the proportion of fibrous particles inthe particles to be formed, it is desired that the ratio between theorganic solvent A and the organic solvent B be adjusted to a preferredrange. The appropriate ratio between the organic solvent A and theorganic solvent B for production of fibrous particles varies widelydepending on, for example, the types of the solvents, and is thusdifficult to uniformly specify. The appropriate weight ratio generallyranges from 5:95 to 95:5, and ranges from 10:90 to 90:10 in many cases.

When the ratio of the organic solvent B to the organic solvent A isbelow the range of ratios that allow formation of fibrous particles, theresultant particles are generally in the form of flakes. In some caseswhere the ratio of the organic solvent B is below but close to theaforementioned range, flakes on the surfaces of which ridge portionslike wrinkles are formed (flakes with wrinkles) are obtained. Theformation of these wrinkles is thought to be due to the fact that thepresence of the organic solvent B causes local differences in theaggregation rate of the colloidal particles.

In some cases where the ratio of the organic solvent B to the organicsolvent A lies in the lower part of the range of ratios that allowformation of fibrous particles, thick fibrous particles are obtained.The formation of such particles is thought to be due to the fact thatridge portions having grown on the edges and surfaces of flakyaggregates are rolled up by the influence of surface tension, and areseparated from the aggregates. In some cases, the thick fibrousparticles include particles that can be considered to be formed by theaggregates themselves having been rolled up. In many cases, the shape inthe longitudinal direction of the thick fibrous particles is distortedbecause of the formation mechanism. The thick fibrous particlestypically have a diameter of 5 μm to 100 μm, and a length of 20 μm 2000μm.

When the ratio of the organic solvent B to the organic solvent A iswithin the range that is very appropriate for formation of fibrousparticles, thin fibrous particles can be obtained. In some cases,spherical fine particles having been deformed are attached to the tipsof the thin fibrous particles. The presence of these fine particlesimplies that the thin fibrous particles are formed through a mechanismdifferent from the mechanism of the formation of the thick fibrousparticles.

The formation of the thin fibrous particles is thought to be due to thefact that fine droplets of the sol are elongated by stirring intofilaments in the liquid phase, and the organic solvent A diffuses in theelongated droplets from around the droplets. It is inferred that, when alimited amount of the organic solvent A diffuses in the droplets of thesol, the droplets having increased viscosities are elongated before thecolloidal particles are aggregated and grow into such a large size thatthe aggregate settles out. The fine particles at the tips of the fibrousparticles are parts of droplets that have not been elongated due toexcessive increase in viscosity. The thin fibrous particles typicallyhave a diameter of 0.5 μm or more and less than 5 μm, and a length of 10μm to 2000 μm.

Even when a liquid appropriate for formation of fibrous particles isused, if droplets of the sol are introduced into the liquid withoutstirring of the liquid, only a very limited amount of fibrous particlesare formed. In order to obtain fibrous particles, it is preferable thatdroplets of the metal oxide sol be introduced while the liquid isstirred.

In many cases where the ratio of the organic solvent B to the organicsolvent A is beyond the range of ratios that allow formation of fibrousparticles, the resultant particles have spherical shapes. The formationof such particles is thought to be due to the fact that the aggregationof colloidal particles is further restricted, and the increase in theviscosity of the sol is made slow, as a result of which the dropletsalmost completely maintain their shapes without being elongated intofilaments. In some cases where the aggregation rate of the colloidalparticles is extremely low, non-spherical particles are formed. This maybe because the droplets are deformed by contact with the wall of acontainer, are combined with each other, or are broken in the course ofaggregation. The blocky particles such as spherical or non-sphericalparticles may be solid or hollow.

It is also possible to obtain fibrous particles using onelow-permittivity polar organic solvent. The properties that alow-permittivity polar organic solvent suitable for formation of fibrousparticles should have vary slightly depending on, for example, the typeof the metal oxide sol. In general, low-permittivity polar organicsolvents that belong to the following three groups F1 to F3 areconsidered to be suitable for formation of fibrous particles.

The first group includes low-permittivity polar-protic organic solventsF1 having a solubility in water of 10 g/100 ml to 30 g/100 ml,particularly 10 g/100 ml to 20 g/100 ml. Examples of the solvents F1include monohydric alcohols having a solubility in water within theabove range and having a molecular weight of preferably 50 to 85,particularly preferably 60 to 80. Examples of such alcohols include2-butanol (solubility in water: 12.5 g/100 ml, molecular weight: 74) and2-butene-1-ol (16.6 g/100 ml, 72). By contrast, 1-butanol which is amonohydric alcohol but has a slightly low solubility in water(solubility in water: 7.8 g/100 and acetylacetone which has anappropriate solubility in water (16 g/100 ml) but is an aprotic solvent,cannot be suitably used alone as a solvent for formation of fibrousparticles.

The second group includes low-permittivity polar organic solvents F2miscible with water, having a viscosity coefficient of 1.3 mPas to 3mPas, and having a molecular weight of 100 or more, particularly 100 ormore and 200 or less. The solvents F2 are preferably glycol ethers suchas diethylene glycol diethyl ether (solubility: co, viscositycoefficient: 1.4 mPas, molecular weight: 162), propylene glycolmonopropyl ether, (∞, 2.8 mPas, 118), and ethylene glycol monoisobutylether (∞, 2.9 mPas, 118). Particularly, the solvents F2 are monoethersor diethers of ethylene glycol, diethylene glycol, triethylene glycol,propylene glycol, dipropylene glycol, and tripropylene glycol. Moreparticularly, the solvents F2 are monoethers or diethers of theseglycols with alkyl groups or alkenyl groups having 1 to 4 carbon atoms(preferably 2 to 4 carbon atoms). By contrast, 2-butoxyethanol(=ethylene glycol monobutyl ether, solubility: ∞, viscosity coefficient:3.2 mPas, molecular weight: 118) having a higher viscosity coefficient,and 2-ethoxyethanol (=ethylene glycol monoethyl ether, ∞, 2.1 mPas, 90)having a smaller molecular weight, are not suitable as a solvent forformation of fibrous particles.

The third group includes low-permittivity polar organic solvents F3 thatdo not belong to the groups F1 and F2. The solvents F3 includepolyhydric alcohols having a low solubility and a high viscositycoefficient such as 2-ethyl-1,3-hexanediol, and poorly-soluble glycolethers such as diethylene glycol monohexyl ether.

It is thought that when a solvent belonging to any of the above groupsF1 to F3 is used, the conditions appropriate for formation of fibrousparticles are satisfied as in the case where a liquid containing theorganic solvent A and the organic solvent B is used. Although thedetailed reasons for this are not clear, it seems that not only thesolubility in water and the relative permittivity, but also theviscosity coefficient and molecular weight of a solvent should be takeninto account as part of factors of formation of fibrous particles. Thereis a possibility that the viscosity coefficient acts as a factor indetermining the shape of particles to be formed in association with thedegree of influence exerted by the surface tension of droplets of thesol on the shape of the droplets, and that the molecular weight acts asa factor in determining the shape of particles to be formed inassociation with the rate of diffusion of the solvent into water.

As illustrated above, in order to obtain fibrous particles, thelow-permittivity polar solvent is preferably at least one selected from2-butanol, 2-butene-1-ol, diethylene glycol diethyl ether, propyleneglycol monopropyl ether, ethylene glycol monoisobutyl ether,2-ethyl-1,3-hexanediol, and diethylene glycol monohexyl ether.

In the method of the present invention, the basic shape of particles isdetermined in the liquid phase. The method of the present invention doesnot require the step of peeling a film formed by applying a metal oxidesol onto a substrate, and is therefore suitable for producing thin flakyparticles. A particularly suitable method for mass production of thinflaky particles is a method using a metal oxide sol previously mixedwith an aqueous high-permittivity organic solvent (organic solvent α)that is miscible with water and that is a protic solvent having arelative permittivity higher than 30, or an aprotic solvent having arelative permittivity higher than 40. The organic solvent a mixed withthe metal oxide sol is thought to control the inter diffusion betweenwater and an organic solvent at the interface around droplets, and thusto contribute to narrowing the region of the interface in which thepermittivity is reduced.

As the aqueous high-permittivity polar organic solvent (organic solventα), an alcohol having two or more hydroxyl groups and having four orless carbon atoms is used, and a diol or a triol is preferred.Specifically, at least one selected from ethylene glycol (relativepermittivity: 39), propylene glycol (relative permittivity: 32),diethylene glycol (relative permittivity: 32), and glycerin (relativepermittivity: 47), is preferred as the organic solvent α.

The mixing ratio by weight between the metal oxide sol and the organicsolvent α is preferably 95:5 to 50:50, and particularly preferably 90:10to 70:30.

When the metal oxide sol that further contains the organic solvent α isused, the thickness of flaky particles is reduced, compared to when theorganic solvent α is not used. This method is suitable for massproduction of flaky particles having a thickness of 0.5 μm or less,particularly 0.4 μm or less, for example, 0.1 μm to 0.4 μm.

Hereinafter, the meanings of the terms about the shapes of particleswill be described. The description of the flaky shape has already beengiven, and is therefore omitted.

In the present specification, the term “fibrous” means the shape of afilament, that is, a long, thin piece. Specifically, the term “fibrous”means the shape of a filament in which the ratio of the length to thediameter is 3 or more. A fibrous particle need not have a uniformdiameter in the length direction, and may have a shape with a portionthicker or thinner than the other portions. In this case, the diameterof the fibrous particle is defined as the diameter of the bottom face ofa cylinder having a volume equal to the volume of the fibrous particle.In addition, the fibrous particle need not extend straight in its lengthdirection, and may have a shape extending in a curved manner. Thediameter of the fibrous particle is preferably 0.5 μm to 100 μm, andmore preferably 1 μm to 10 μm. The length of the fibrous particle ispreferably 3 μm to 2 mm, and more preferably 10 μm to 500 μm. The ratioof the diameter to the length in the fibrous particle is preferably 5 to100.

As described above, fibrous particles may have a large diameter or mayhave a small diameter, depending on different formation mechanisms. Inthe present specification, fibrous particles each having a diameter of 5μm to 100 μm are referred to as “thick fibers”, while fibrous particleseach having a diameter of 0.5 μm to 10 μm, particularly a diameter of0.5 μm or more and smaller than 5 μm, are referred to as “thin fibers”.In EXAMPLES, the thin fibers are simply referred to as “fibers”.

In the present specification, the term “blocky” means the shape of anagglomerate that cannot be categorized as a flake or a fiber, andtypically means a spherical shape. A blocky particle in which the ratioof the maximum diameter to the minimum diameter ranges from 1 to 1.5 isreferred to as a spherical particle, and the other types of blockyparticles are referred to as non-spherical particles. The diameter ofthe spherical particle is preferably 1 μm to 100 μm, and more preferably5 μm to 50 μm. The ratio of the maximum diameter to the minimum diameterin the spherical particle is preferably 1 to 1.2.

In general, particles obtained by the production method described aboveeach have a maximum dimension of 2 mm or less.

Functional materials may be previously added to the metal oxide sol.Examples of the functional materials include materials that function asat least one selected from a water repellent agent, an antibacterialagent, an ultraviolet absorber, an infrared absorber, a coloring agent,an electric conductor, a heat conductor, a fluorescent material, and acatalyst. Here, the “heat conductor” means a material having a higherheat conductivity than any of the oxides, such as silicon oxide and tinoxide, listed above as constituent oxides of metal oxide colloidalparticles. In addition, the term “catalyst” used herein is intended toinclude photocatalysts. It should be noted that some functionalmaterials may perform a plurality of functions. For example, titaniumoxide (titania) is a material functioning as an ultraviolet absorber anda catalyst (photocatalyst), and carbon black is a material functioningas a coloring agent, an electric conductor, and a heat conductor.

Examples of the functional material are listed below.

Water repellent agent: fluoroalkylsilane compounds, alkylsilanecompounds, and fluororesins.

Antibacterial agent: silver, copper, silver compounds, copper compounds,zinc compounds, quaternary ammonium salts, and alkyldiaminoethylglycinehydrochloride.

Ultraviolet absorber: titanium oxide, zinc oxide, cerium oxide, ironoxide, cinnamic acid compounds, para-amino benzoic acid compounds,benzophenone compounds, benzotriazole compounds, salicylic acidcompounds, phenol triazine compounds, alkyl benzoate compounds, arylbenzoate compounds, cyanoacrylate compounds, dibenzoylmethane compounds,chalcone compounds, and camphor compounds.

Infrared absorber: antimony-doped tin oxide, tin-doped indium oxide,diimmonium compounds, phthalocyanine compounds, benzenedithiol metalliccompounds, anthraquinone compounds, and aminothiophenolate metalliccompounds.

Coloring agent: microcrystalline cellulose; inorganic white pigmentssuch as titanium dioxide and zinc oxide; inorganic red pigments such asiron oxide (colcothar) and iron titanate; inorganic brown pigments suchas γ-iron oxide; inorganic yellow pigments such as yellow iron oxide andocher; inorganic black pigments such as black iron oxide and carbonblack; inorganic purple pigments such as manganese violet and cobaltviolet; inorganic green pigments such as chromium oxide, chromiumhydroxide, and cobalt titanate; inorganic blue pigments such asultramarine and Prussian blue; metal powder pigments such as aluminumpowder and copper powder; organic pigments such as Red No. 201, Red No.202, Red No. 204, Red No. 205, Red No. 220, Red No. 226, Red No. 228,Red No. 405, Orange No. 203, Orange No. 204, Yellow No. 205, Yellow No.401, and Blue No. 404; organic pigments such as zirconium lakes, bariumlakes and aluminum lakes of Red No. 3, Red No. 104, Red No. 106, Red No.227, Red No. 230, Red No. 401, Red No. 505, Orange No. 205, Yellow No.4, Yellow No. 5, Yellow No. 202, Yellow No. 203, Green No. 3, and BlueNo. 1; and natural dyes such as cochineal dye, lac dye, monascus dye,monascus yellow dye, gardenia red dye, gardenia yellow dye, safflowerred dye, safflower yellow dye, beet red, turmeric dye, red cabbage dye,chlorophyll, β-carotene, spirulina dye, and cacao dye.

Electric conductor: metals such as copper, gold, and platinum; and metaloxides such as tin oxide, antimony-doped tin oxide, tin-doped indiumoxide, metal-doped zinc oxide, and metal-doped titanium oxide.

Heat conductor; metals such as copper, boron nitride, aluminum nitride,silicon nitride, diamond, carbon nanotube, carbon black, and graphite.

Fluorescent material: fluorescein dyes, pyrazine dyes, coumarin dyes,naphthalimide dyes, triazine dyes, oxazine dyes, dioxazine dyes,rhodamine dyes, sulforhodamine dyes, azo compounds, azomethinecompounds, stilbene derivatives, oxazole derivatives, benzoxazole dyes,imidazole dyes, pyrene dyes, terbium-activated gadolinium oxide, calciumtungstate fluorescent materials, europium-activated bariumchlorofluoride fluorescent materials, and zinc oxide fluorescentmaterials.

Catalyst: platinum, palladium, rhodium, iridium, ruthenium, iron oxide,gold, metal complexes, titanium oxide, zinc oxide, cadmium sulfide, andtungsten oxide.

When a functional material is added, the resultant particles contain thefunctional material in addition to a metal oxide. With the presentinvention, it is also possible to obtain particles that contain afunctional material but have a low proportion of the functional materialexposed to the outside. Therefore, for example, highly safe products canbe provided for uses for which the influence of nanoparticles on thehuman body should be taken into account. Titania fineparticle-containing flaky silica particles obtained by the presentinvention are useful in the field of cosmetics as a base material forfoundations that provides ultraviolet shielding performance whilepreventing contact between the titania fine particles and the humanbody.

Metal oxide particles having mesopores with an average pore diameter of10 nm or more can be obtained by the production method described above.Particles having mesopores with an average pore diameter of 10 nm ormore cannot be obtained by drying a metal oxide sol as it is, or bygelatinizing a sol applied onto a substrate, and peeing the resultantgel. Mesopores with a large pore diameter are thought to be formed bymetal oxide colloidal particles that are aggregated in a liquid in sucha manner that spaces are maintained among the colloidal particles. Withthe present invention, mesoporous particles containing a metal oxide canbe produced even at ordinary temperature and pressure without use of asurfactant. For example, the mesoporous particles are formed byaggregation of particles of at least one metal oxide selected fromsilicon oxide, titanium oxide, zirconium oxide, aluminum oxide, tantalumoxide, niobium oxide, cerium oxide, and tin oxide.

With the present invention, mesoporous particles having a high porositycan also be produced. With the present invention, it is possible toobtain mesoporous particles having a porosity of 30% or more, preferably40% or more, more preferably 50% or more, particularly preferably 60% ormore, for example, 60% to 80%.

The specific surface area of the mesoporous particles that can beobtained by the present invention is preferably 50 m²/g to 500 m²/g,more preferably 100 m²/g to 300 m²/g, and particularly preferably 150m²/g to 250 m²/g, for example, 150 m²/g to 200 m²/g. With theconventional production method using a surfactant, pore channels areformed in the resultant mesoporous particles, and the specific surfacearea of the mesoporous particles is therefore much greater than 500m²/g. In addition, the pore volume of the mesoporous particles of thepresent invention is preferably 0.17 cc/g or more, more preferably 0.25cc/g or more, particularly preferably 0.43 cc/g or more, and especiallypreferably 0.5 cc/g or more, for example, 0.5 cc/g to 0.9 cc/g. Theaverage pore diameter of the mesoporous particles is preferably 10 nm to40 nm, more preferably 10 mm to 30 nm, and particularly preferably 15 nmto 25 nm. The mesopores having such a size are suitable for taking inmacromolecules such as proteins.

The mesoporous particles of the present invention are useful as acatalyst carrier, a filter material, an absorbing material, a humidityconditioning material, a heat insulating material, a base material forhigh-performance ultraviolet shielding, a base material for cosmetics, alow dielectric material, or the like. When the mesoporous particles inthe form of flakes are used as a base material for a foundation, thefoundation can have characteristics, such as having good extensibility,having excellent adhesion to skins, causing less unevenness during use,and having excellent absorbency for sweat and sebum.

In addition, the present invention allows mass production of flakymesoporous particles having a single-layer structure. As far as thepresent inventors know, any production methods suitable for massproduction of flaky mesoporous particles have not been reported in thepast. This is because flaky mesoporous bodies cannot be obtained by asol-gel method using a surfactant micelle as a template, since in thesol-gel method, a metal oxide surrounds rod-shaped micelles, and theparticle grows three-dimensionally.

It is known that mesoporous particles each composed of tabular crystalsassembled together are obtained by using a layered silicate as a silicasource. However, the porous bodies are generally formed in a shape farfrom being flaky. Even if the porous bodies are formed in a shape thatcan be regarded as flaky, the porous bodies do not have a single-layerstructure, but have a multi-layer structure. Furthermore, in themulti-layer structure, the mesopores extend along the interlayerportions. By contrast, the present invention makes it possible to obtainflaky mesoporous particles that have a single-layer structure formed bymetal oxide colloidal particles aggregated into a flake, that havemesopores formed between the aggregated colloidal particles, and thathave high mechanical strength.

The flaky mesoporous particles that can be obtained by the presentinvention can also be mesoporous bodies internally including variousfunctional materials. For example, the functional materials arematerials that function as at least one selected from a water repellentagent, an antibacterial agent, an ultraviolet absorber, an infraredabsorber, a coloring agent, an electric conductor, a heat conductor, afluorescent material, and a catalyst. Depending on the types offunctional materials contained inside the mesoporous particles, themesopores may greatly help the materials perform their functionseffectively. The mesoporous particles “internally including” functionalmaterials may contain functional materials exposed on the surfaces ofthe mesoporous particles, in addition to functional materials containedinside the mesoporous particles.

Examples of such mesoporous particles include a mesoporous particleinternally including titanium oxide. The particle is a mesoporousparticle which contains the titanium oxide therein and in which thetitanium oxide communicates with the outside of the particle via themesopores. Organic substances contained in the atmosphere outside theparticle come into contact with the titanium oxide via the mesopores ofthe particle. Therefore, for example, decomposition of the organicsubstances is allowed to proceed effectively by the photocatalyticfunction exerted by the titanium oxide. Thus, the mesopores contributeto increasing the area of contact between the outside atmosphere and afunctional material contained inside the particle, and thus tofacilitating the exertion of the function of the functional material.

If a functional material is added to the flaky particle (mesoporousparticle) that can be obtained by the present invention, a particlehaving an improved uniformity of distribution of the functional materialcan be obtained. In the method of the present invention, metal oxidecolloidal particles are aggregated in such a manner that spaces aremaintained among the colloidal particles. Therefore, a functionalmaterial as typified by titanium oxide is also distributed in theparticle in such a manner that spaces are maintained among thedistributed portions of the functional material. Accordingly, in theparticle, the functional material is less likely to be unevenlydistributed, and is distributed more uniformly than in silica particlesobtained by peeling a film formed by applying a silica sol onto asubstrate. In the particle, projective overlap between distributedportions of the functional material is small. Therefore, for example,titanium oxide can exhibit ultraviolet shielding performance withincreased effectiveness. The content of the titanium oxide in the flakyparticles that can be obtained by the present invention is preferably20% by weight to 45% by weight.

In many of the commercially-available metal oxide sols that have a pH of7 or higher and that can be used in the method of the present inventionas a source of metal oxide, cations contained are an alkali metal ion,particularly, sodium ion (Nat). When such a commercially-availableproduct is used, sodium ions are contained in the resultant particles.Typically, the sodium concentration in the particles is only 1% byweight to 2% by weight in terms of oxide content (in terms of Na₂Ocontent). However, the allowable sodium concentration is lower for someparticular uses such as use as a material for an electronic device. Whenit is necessary to meet such requirements, the sodium concentration canbe reduced to a certain degree by washing the particles with an acidsuch as hydrochloric acid. However, the addition of the washing stepincreases the production cost. Therefore, in the case where the sodiumconcentration should be low, it is preferable to use a metal oxide solwhose major cation is an ion other than alkali metal ions, such asammonium ion (NH₄ ⁺). As used herein, the term “major cation” means acation whose content by weight is the largest. In a preferred embodimentof the production method of the present invention, the metal oxide solcontains an ion other than alkali metal ions as the major cation.

If a metal oxide sol whose major cation is an ion other than alkalimetal ions is used, the sodium concentration in terms of Na₂O content inthe particles can be reduced to less than or equal to 0.7% by weight,even less than 0.5% by weight, and particularly less than 0.3% byweight. However, since even such a sol generally contains a slightamount of sodium ion, it is difficult to completely prevent sodium frombeing contained in the particles. For example, the sodium concentrationin the particles is 0.001% by weight to 0.7% by weight in terms of oxidecontent (in terms of Na₂O content).

When the method of the present invention is carried out using metaloxide colloidal particles contained in a metal oxide sol whose majorcation is an ion other than alkali metal ions, it is observed that thereis a tendency that the metal oxide colloids are less prone toaggregation, and the yield of aggregates is lower than when a metaloxide sol whose cation is an alkali metal ion is used. In order tocompensate for this tendency, it is advantageous to facilitateaggregation of metal oxide colloids by previously adding the same cationas the major cation contained in a metal oxide sol used, to a liquidinto which the sol is to be fed. In the case where the major cation isammonium ion, dissolving ammonium ion previously in the liquid increasesthe yield of aggregates. In this case, the concentration of the “majorcation” in the liquid is preferably 0.01% by weight or more, and morepreferably 0.02% by weight or more, for example, 0.05% by weight to 3%by weight.

Another method for facilitating aggregation of a metal oxide sol whosemajor cation is an ion other than alkali metal ions is to add, to thesol, metal oxide colloidal particles that have a stronger cohesive forcethan metal oxide colloidal particles contained in the sol. The cohesiveforce of colloidal particles can be evaluated by the Hamaker constant.From this standpoint, metal oxide colloidal particles suitable forfacilitating aggregation of a silica sol (silicon oxide sol) aretitanium oxide colloidal particles and tin oxide colloidal particles,and are particularly tin oxide colloidal particles. In a preferredembodiment of the production method of the present invention, the metaloxide sol contains silicon oxide colloidal particles, and also containsat least one selected from titanium oxide colloidal particles and tinoxide colloidal particles.

EXAMPLES Example 1

An amount of 50 ml of each of the organic solvents listed in Table 1 wasput in a beaker, and a total amount of 1 g of an alkaline silica sol(“SILICADOL 30S” manufactured by Nippon Chemical Industrial Co., Ltd.)was added in drops of 0.01 g each to the organic solvent. The SILICADOL30S is a colloidal silica whose dispersion medium is water and which hasa pH of 9.0 to 10.5, and contains colloidal particles having a particlediameter of 7 nm to 10 nm. During the dropping of the alkaline silicasol, the organic solvent was stirred with a magnetic stirrer (rotationalspeed: 800 rpm).

Next, aggregates of colloidal particles were separated by centrifugationfrom the solvent in which the colloidal particles had been aggregated toform a slurry. The aggregates were washed with 2-propanol, and then2-propanol was removed by decantation. The obtained aggregates of thecolloidal particles were dried in a vacuum dryer set at 150° C. toobtain a silica powder (an assemblage of silica particles). Finally, thedried silica powder was burned at 700° C. for 5 hours. The weight of theobtained powder was about 0.2 g to 0.25 g. The shapes of the burnedsilica particles were observed, and categorized into a flaky shape, ablocky shape (a spherical or non-spherical shape), and a fibrous shape(thick fibers or thin fibers, thin fibers are simply described as“fibers”), based on the shape categorization described above. Theresults are shown in Table 1.

In all of the tables provided below, the unit of the solubility is g/100ml. The values of the relative permittivity, the solubility, and theviscosity coefficient are values measured at 20° C. Furthermore, in theboxes of “Shape of particles”, the shapes are listed in descending orderof the number of formed particles.

TABLE 1 Relative Solubility Shape of No Organic solvent Typepermittivity in water particles C0 Aminoethanol Polar 38 ∞ (NA) C1Methanol protic 33 ∞ (NA)  1 Ethanol solvent 24 ∞ Flakes  2 1-propanol(n-propyl alcohol) 22 ∞ Flakes  3 2-propanol(isopropyl alcohol) 18 ∞Flakes  4 1-butanol (n-butyl alcohol) 17 7.8 Spheres, Non-spheres  52-butanol (sec-butyl alcohol) 16 12.5 Fibers, spheres, flakes  62-methyl-1-propanol (isobutyl alcohol) 18 8.5 Spheres, Non-spheres  72-methyl-2-propanol(tert-butyl alcohol) 11 ∞ Flakes  8 1-pentanol(n-amyl alcohol) 14 2.4 Spheres, Non-spheres  9 3-methyl-1-butanol(isopentyl alcohol) 15 2.4 Spheres, Non-spheres 10 3-methyl-2-butanol(tert-pentyl alcohol) 6 2.4 Spheres, Non-spheres 11 1-hexanol (n-hexylalcohol) 13 0.6 Non-spheres 12 1-octanol (n-octyl alcohol) 10 0.054Non-spheres 13 Benzyl alcohol 13 3.8 Spheres 14 2-propene-1-ol (allylalcohol) 22 ∞ Flakes 15 Ethylene glycol monoethyl ether 30 ∞ Flakes(2-ethoxyethanol) 16 Ethylene glycol monomethyl ether 17 ∞ Flakes(2-methoxyethanol) 17 Ethylene glycol mono-n-butyl ether 10 ∞ Flakes(2-butoxyethanol) 18 Acetic acid (glacial acetic acid) 6.2 ∞ Flakes C2Formamide Polar 111 ∞ (NA) C3 Dimethyl sulfoxide aprotic 49 ∞ (NA) 19Acetonitrile solvent 38 ∞ Flakes 20 Acetone 21 ∞ Flakes 21 Ethylacetoacetate 16 12 Spheres, Flakes 22 Pyridine 12 ∞ Flakes 232-metylpyridine (2-picoline) 9.5 ∞ Flakes 24 Ethylene glycol monomethylether acetate 8.3 ∞ Flakes 25 Tetrahydrofuran 7.6 ∞ Flakes 26 Morpholine7.4 ∞ Flakes 27 Ethylene glycol dimethyl ether 5.5 ∞ Flakes 281,4-dioxane 2.2 ∞ Flakes C4 n-hexane 1.9 0.001 (NA) C0 to C4 arecomparative examples, and n-hexane of C4 is a non-polar solvent.Observation results of the powder obtained from No. 3 (2-propanol) areshown in FIGS. 1 and 2, and an observation result of the powder obtainedfrom No. 12 (1-octanol) is shown in FIG. 4. NA: Not aggregated

Polar protic solvents having a relative permittivity higher than 30 andpolar aprotic solvents having a relative permittivity higher than 40cannot sufficiently reduce electrical repulsion between colloidalparticles. Therefore, when a metal oxide sol was dropped into a solventthat falls under the category of these types of solvents, the colloidalparticles maintained the dispersion state. In addition, n-hexane whichhas a solubility in water less than 0.05 g/100 ml is a low-permittivitysolvent, but does not fall under the category of polar solvents.Accordingly, n-hexane cannot cause aggregation of colloidal particles.By contrast, when a low-permittivity polar solvent was used, colloidalparticles were aggregated. Specifically, when an aqueouslow-permittivity polar organic solvent was used, only flaky particleswere obtained. On the other hand, when a non-aqueous low-permittivitypolar organic solvent was used, various shapes of particles wereobtained. It is noticeable that the number of fibrous particles was thelargest among particles obtained by using 2-butanol. When a non-aqueouslow-permittivity polar organic solvent having a solubility in water lessthan 2 g/100 ml was used, only non-spherical particles were obtained.

Further experiments were performed in the same manner as describedabove, except that other types of organic solvents were used. It wasconfirmed that results similar to the above results can be obtained alsowhen the other types of solvents are used. For example, when any ofethylene glycol monophenyl ether (2-phenoxyethanol), 1,5-pentanediol,N-methyl-2-pyrrolidone, and 1,3-dioxolane which are low-permittivitypolar solvents was used, aggregation of colloidal particles wasobserved. The shapes of particles also showed a tendency similar to theabove. When 2-phenoxyethanol having a low solubility in water (2.5 g/100ml) was used, spherical particles were obtained (see FIG. 3; sphericalparticles having a particle diameter larger than 15 μm), whereas whenany of the other three solvents having a high solubility in water wasused, flaky particles were obtained. On the other hand, when isopropylmyristate which is a non-polar solvent was used, colloidal particleswere not aggregated.

Example 2

An amount of 50 ml of 2-propanol (isopropyl alcohol) was put in abeaker, and a total amount of 1 g of each of the silica sols (colloidalsilicas) listed in Table 2 was added in drops of 0.01 g each to the2-propanol. During the dropping of the silica sol, the 2-propanol wasstirred with a magnetic stirrer (rotational speed: 800 rpm). Thereafter,the same steps as in Example 1 were performed to obtain a silica powder.The results are shown in Table 2.

TABLE 2 Colloidal particle Metal oxide sol diameter Shape of No(Colloidal silica) pH (nm) particles C30 SNOWTEX-O 2 to 4 10 to 20 (NA)C31 SNOWTEX-OL 2 to 4 40 to 50 (NA) 31 SNOWTEX-XS  9.0 to 10.0 4 to 6Flakes 32 SNOWTEX-20  9.5 to 10.0 10 to 20 Flakes 33 SNOWTEX-20L  9.5 to11.0 40 to 50 Flakes 34 SNOWTEX-30  9.5 to 10.5 10 to 20 Flakes 35SNOWTEX-N  9.0 to 10.0 10 to 20 Flakes (see the footnotes) 36 SNOWTEX-UP 9.0 to 10.5  40 to 100 Flakes (chain-like particles) C32 SNOWTEX-OUP 2to 4  40 to 100 (NA) (chain-like particles) 37 SNOWTEX-C 8.5 to 9.0 10to 20 Flakes 38 SNOWTEX-S  9.5 to 10.5  8 to 11 Flakes 39 SILICADOL 20 9.5 to 10.5 10 to 20 Flakes C30 to C32 are comparative examples. All ofthe “SNOWTEX” series are manufactured by Nissan Chemical Industries,Ltd., and “SILICADOL 20S” is manufactured by Nippon Chemical IndustrialCo., Ltd. In the case of the sample No. 35 for which “SNOWTEX-N” wasused, more colloidal particles remained dispersed than in the case ofthe other samples.

Hydration energy makes a large contribution to the stabilization of anacidic silica sol, unlike in the case of an alkaline silica sol.Therefore, when an acidic silica sol was dropped into a low-permittivitypolar organic solvent, the colloidal particles maintained the dispersionstate. When an alkaline silica sol is used, the colloidal particles areaggregated even if the colloidal particles in the sol have a very smallparticle diameter or are dispersed in the state of being connected in achain.

When “SNOWTEX-N” was used, the yield of aggregates of the colloidalparticles was lower than when any of the other alkaline sols was used.This is because the major cation contained in the sol is ammonium ion(NH₄ ⁺), while the major cation contained in the other sols is sodiumion (Na⁺). In the case of using a sol containing a low ion-intensityalkali component such as ammonium ion, aggregation of the colloidalparticles can be facilitated by previously adding the ion to a liquidinto which the sol is to be dropped. When ammonia was previously addedto 2-propanol, the degree of aggregation of the colloidal particles wasincreased even when “SNOWTEX-N” was dropped. Generally, in the case ofdropping an alkaline metal oxide sol in which the content of ammoniumion is larger than that of alkali metal ions, ammonium ion is preferablyadded in advance to a liquid into which the sol is to be dropped. Anexample of measurement of the sodium ion concentration in particlesobtained from a metal oxide sol whose major cation is ammonium ion willbe described later (Example 12).

Example 3

Silica powders were obtained in the same manner as in Example 1, exceptthat organic solvents (low-permittivity polar organic solvents) listedin Table 3 were used. The relative permittivities of all the solvents inTable 3 are 30 or lower. The results are shown in Table 3.

TABLE 3 Viscosity Solubility coefficient Molecular Shape of NoLow-permittivity polar organic solvent in water (mPas) weight particles 5 2-butanol (sec-butyl alcohol) F1 12.5 4.2  74 Fibers, spheres, flakes41 2-butene-1-ol (crotyl alcohol) F1 16.6 —  72 Fibers, spheres, flakes42 Diethylene glycol diethyl ether F2 ∞ 1.4 162 Flakes, thick fibers 43Propylene glycol monopropyl ether F2 ∞ 2.8 118 Thick fibers, flakes,spheres 44 Ethylene glycol monoisobutyl ether F2 ∞ 2.9 118 Fibers,flakes, (2-isobutoxyethanol) spheres 45 2-ethyl-1,3-hexanediol F3  4.2323 146 Spheres, fibers 46 Diethylene glycol monohexyl ether F3  1.7 8.6145 Fibers, flakes, (2-(2-hexyloxyethoxy)ethanol) spheres

In the samples No. 41-46, part of the particles were in the form offibers as in the sample No. 5. The solvents belong to any one of theabove groups F1 to F3, and have the properties suitable for formingfibers. By contrast, as shown in Table 1, fibrous particles were notobtained by using 1-butanol having a lower solubility in water (7.8g/100 ml) than the solvents of the group F1, 2-butoxyethanol having ahigher viscosity coefficient (3.2 mPas) than the solvents of the groupF2, or 2-ethoxyethanol having a smaller molecular weight (90) than thesolvents of the group F2.

In order to obtain flaky particles, an aqueous low-permittivity organicsolvent is preferably used. However, as shown in Table 3, there are alsonon-aqueous low-permittivity organic solvents that allow part of theresultant particles to take the form of flakes, such as solventsbelonging to the categories F1 and F2.

Example 4

Silica powders were obtained in the same manner as in Example 1, exceptthat mixed solvents of aqueous low-permittivity organic solvents(organic solvents A) and non-aqueous low-permittivity organic solvents(non-aqueous low-permittivity polar organic solvents (organic solventsB1) or non-aqueous low-permittivity non-polar organic solvents (organicsolvent B2)) were used. The organic solvents A, B1, and B2 are listed inTables 5 to 19. The solubilities in water and the viscosity coefficientsof the organic solvents B1 used are shown in Table 4. As the organicsolvents B2, n-hexane (relative permittivity: 1.89) and n-heptane(relative permittivity: 1.94) were used. The relative permittivities ofall of the organic solvents A and the organic solvents B1 which wereused were 30 or lower. The results are shown in Table 5 and thesubsequent tables.

TABLE 4 Viscosity Organic solvent B1 Solubility in water coefficient(mPas) 2-phenoxyethanol 2.5 30.5 Methyl ethyl ketone 22.6 0.42Acetylacetone 16 <1 Cyclohexanone 8.7 <2.2 1-butanol 7.8 3.0 Benzylalcohol 3.8 <7.8 2-butoxyethyl acetate 1.1 1.8 2-ethyl-1-hexanol 0.079.8

TABLE 5 Organic solvent A Organic solvent B1 2-ethoxyethanol2-phenoxyethanol No. (% by weight) (% by weight) Shape of particles 5183.3 16.7 Flakes 52 66.7 33.3 Flakes 53 50.0 50.0 Flakes 54 33.3 66.7Flakes (with many wrinkles) 55 16.7 83.3 Fibers, spheres

TABLE 6 Organic solvent A Organic solvent B1 2-butoxyethanol2-phenoxyethanol No. (% by weight) (% by weight) Shape of particles 6170.0 30.0 Flakes, fibers, spheres 62 60.0 40.0 Flakes, fibers, spheres63 50.0 50.0 Fibers, flakes, spheres 64 40.0 60.0 Spheres, flakes,fibers 65 30.0 70.0 Spheres (flakes, fibers) The amount of the particlesobserved to have the shapes parenthesized in No. 65 was small.Observation results of the powder obtained from No. 61 are shown inFIGS. 5 and 6, and an observation result of the powder obtained from No.65 is shown in FIG. 7.

TABLE 7 Organic solvent A Organic solvent B1 2-butoxyethanol2-ethoxyethanol 2-phenoxyethanol Shape of No. (% by weight) (% byweight) (% by weight) particles 71 42.9 42.9 14.3 Flakes 72 33.3 33.333.3 Flakes 73 37.5 25.0 37.5 Flakes 74 40.0 20.0 40.0 Flakes 75 14.342.9 42.9 Flakes 76 42.9 14.3 42.9 Fibers, flakes 77 45.5  9.1 45.5Fibers, flakes 78 47.6  4.8 47.6 Fibers, flakes An observation result ofthe powder obtained from No. 77 is shown in FIG. 8.

TABLE 8 Organic solvent A Organic solvent B1 2-butoxyethanol 1-butanolNo. (% by weight) (% by weight) Shape of particles 81 50.0 50.0 Fibers,spheres, flakes

TABLE 9 Organic solvent A Organic solvent B1 2-butyl carbitol1-phenoxyethanol No. (% by weight) (% by weight) Shape of particles 9150.0 50.0 Fibers, spheres, flakes

TABLE 10 Organic solvent B1 Organic solvent A 1-phenoxy- 2-butoxyethyl2-butoxyethanol ethanol (% acetate Shape of No. (% by weight) by weight)(% by weight) particles 101 63.6 27.3 9.1 Fibers, flakes, spheres

TABLE 11 Organic solvent A Organic solvent B1 2-propanol2-ethyl-1-hexanol No. (% by weight) (% by weight) Shape of particles 11180.0 20.0 Flakes 112 70.0 30.0 Flakes (with many wrinkles) 113 65.0 35.0Flakes (with many wrinkles), thick fibers 114 60.0 40.0 Thick fibers 11555.0 45.0 Fibers, (deformed) spheres 116 50.0 50.0 Spheres, fibers 11745.0 55.0 Spheres, fibers 118 40.0 60.0 Spheres 119 20.0 80.0 Spheres

TABLE 12 Organic solvent A Organic solvent B1 2-propanol 1-butanol No.(% by weight) (% by weight) Shape of particles 121 50.0 50.0 Flakes 12240.0 60.0 Flakes (including flakes with many wrinkles), thick fibers 12335.0 65.0 Fibers, (deformed) spheres, flakes 124 30.0 70.0 Fibers,(deformed) spheres, flakes 125 25.0 75.0 Fibers, (deformed) spheres,flakes 126 20.0 80.0 Spheres, fibers, flakes 127 10.0 90.0 Spheres

TABLE 13 Organic solvent A Organic solvent B1 2-propanol AcetylacetoneNo. (% by weight) (% by weight) Shape of particles 131 50.0 50.0 Flakes132 40.0 60.0 Flakes (with many wrinkles), thick fibers 133 30.0 70.0Thick fibers, flakes (with many wrinkles) 134 20.0 80.0 Fibers,(deformed) spheres

TABLE 14 Organic solvent A Organic solvent B1 2-propanol Benzyl alcoholNo. (% by weight) (% by weight) Shape of particles 141 70.0 30.0 Flakes142 50.0 50.0 Flakes 143 45.0 55.0 Flakes (including flakes with manywrinkles), thick fibers 144 40.0 60.0 Thick fibers, flakes (includingflakes with many wrinkles) 145 35.0 65.0 Fibers, (deformed) spheres 14630.0 70.0 Fibers, spheres 147 20.0 80.0 Spheres

TABLE 15 Organic solvent A Organic solvent B1 Acetone Methyl ethylketone No. (% by weight) (% by weight) Shape of particles 151 50.0 50.0Flakes 152 40.0 60.0 Flakes 153 30.0 70.0 Flakes (including flakes withmany wrinkles) 154 20.0 80.0 Flakes (including flakes with manywrinkles) 155 17.0 83.0 Thick fibers, flakes (including flakes with manywrinkles) 156 15.0 85.0 Thick fibers, flakes 157 10.0 90.0 Fibers,(deformed) spheres, flakes 158 5.0 95.0 Spheres, non-spheres, fibers

TABLE 16 Organic solvent A Organic solvent B1 Acetone Cyclohexanone No.(% by weight) (% by weight) Shape of particles 161 80.0 20.0 Flakes(including flakes with many wrinkles) 162 60.0 40.0 Flakes (includingflakes with many wrinkles) 163 50.0 50.0 Flakes (including flakes withmany wrinkles) 164 40.0 60.0 Flakes (including flakes with manywrinkles) 165 35.0 65.0 Flakes (including flakes with many wrinkles),thick fibers 166 30.0 70.0 Thick fibers, fibers, flakes (with manywrinkles) 167 25.0 75.0 Fibers, thick fibers, (deformed) spheres 16820.0 80.0 Spheres, non-spheres, fibers

TABLE 17 Organic solvent A Organic solvent B2 2-propanol n-hexane No. (%by weight) (% by weight) Shape of particles 171 90.0 10.0 Flakes(including flakes with many wrinkles) 172 80.0 20.0 Flakes (includingflakes with many wrinkles) 173 70.0 30.0 Flakes (including flakes withmany wrinkles) 174 60.0 40.0 Flakes (including flakes with manywrinkles), thick fibers 175 50.0 50.0 Flakes (including flakes with manywrinkles), thick fibers 176 46.0 54.0 Thick fibers, flakes (includingflakes with many wrinkles) 177 40.0 60.0 Thick fibers 178 30.0 70.0Fibers, (deformed) spheres 179 25.0 75.0 Fibers, spheres (includingdeformed spheres) 180 20.0 80.0 Spheres, non-spheres

TABLE 18 Organic solvent A Organic solvent B2 2-propanol n-heptane No.(% by weight) (% by weight) Shape of particles 181 90.0 10.0 Flakes(including flakes with many wrinkles) 182 80.0 20.0 Flakes (with manywrinkles) 183 70.0 30.0 Flakes (with wrinkles) 184 60.0 40.0 Flakes(with wrinkles) 185 50.0 50.0 Thick fibers, flakes (including flakeswith many wrinkles) 186 40.0 60.0 Fibers, thick fibers 187 30.0 70.0Fibers, (deformed) spheres 188 22.0 78.0 Non-spheres, spheres, fibers189 21.0 79.0 Spheres, fibers 190 20.0 80.0 Non-spheres

TABLE 19 Organic solvent A Organic solvent B2 1,4-dioxane n-heptane No.(% by weight) (% by weight) Shape of particles 191 90.0 10.0 Flakes(including flakes with many wrinkles) 192 85.0 15.0 Flakes (with manywrinkles), (distorted) thick fibers 193 80.0 20.0 (Distorted) thickfibers, flakes (with many wrinkles) 194 75.0 25.0 (Distorted) thickfibers, fibers, (distorted) spheres 195 73.0 27.0 (Distorted) spheres,(distorted) thick fibers 196 72.0 28.0 Non-spheres, fibers 197 70.0 30.0Non-spheres, fibers 198 50.0 50.0 Non-spheres

As the affinity for water of the liquid into which droplets of a silicasol are introduced decreases, the shape of the particles shifts fromflakes to fibers, and to spheres or non-spheres. The mixing ratio of thesolvents that allows a high proportion of fibers varies depending on thetypes of the solvents.

In order to obtain flaky particles, an aqueous low-permittivity organicsolvent is preferably used. However, as shown in Tables 5 to 19, atleast part of the particles can be obtained in the form of flakes alsoby using a mixed solvent of an aqueous low-permittivity organic solvent(organic solvent A) and a non-aqueous low-permittivity organic solvent.

Example 5

Metal oxide powders were obtained in the same manner as in Example 1,except that metal oxide sols and organic solvents listed in Table 20were used. The results are shown in Table 20.

TABLE 20 Metal oxide sol Particle Metal diameter No. Product name oxide(nm) pH Organic solvent Shape of particles 201 Ceramace S-8 SnO₂ 2 102-propanol Flakes 202 Ceramace S-8 SnO₂ 2 10 Acetone Flakes 203 CeramaceS-8 SnO₂ 2 10 Mixed solvent Fibers, spheres 204 Biral Al-L7 Al₂O₃ 30 7to 8 2-propanol Flakes 205 Biral Al-L7 Al₂O₃ 30 7 to 8 Acetone Flakes206 Biral Al-L7 Al₂O₃ 30 7 to 8 2-phenoxyethanol Spheres 207 NeedlalP-10 CeO₂ 8  7 Mixed solvent Spheres, flakes, fibers 208 Tynoc A-6L TiO₂10 10 Mixed solvent Spheres, flakes, fibers 209 SNOWTEX XL SiO₂ 40 to 60 9.0 to 10.0 Mixed solvent Spheres, thick fibers, flakes 61 SILICADOL30S SiO₂  7 to 10  9.0 to 10.5 Mixed solvent Flakes, fibers, spheres“SNOWTEX XL” is manufactured by Nissan Chemical Industries, Ltd., andall of the other sols are manufactured by Taki Chemical Co., Ltd. Theparticle diameters are particle diameters of metal oxide colloidalparticles contained in the sols. Mixed solvent = 2-butoxyethanol (70% byweight) + 2-phenoxyethanol (30% by weight) An observation result of thepowder obtained from No. 203 is shown in FIG. 9.

Example 6

A sol for dropping was prepared by mixing an alkaline silica sol(“SILICADOL 30S” manufactured by Nippon Chemical Industrial Co., Ltd.;see Example 1) and glycerin at a weight ratio of 80:20. An amount of 50ml of 2-propanol was put in a beaker, and a total amount of 1 g of thesol for dropping was added in drops of 0.01 g each to the 2-propanol.During the dropping of the sol for dropping, the 2-propanol was stirredwith a magnetic stirrer. Thereafter, the same steps as in Example 1 wereperformed to obtain a silica powder (see FIG. 10).

The particles obtained had a flaky shape, and had a thickness rangingfrom 0.3 μm to 0.4 μm. The thickness of the flaky particles was smallerthan the thickness (0.5 μm to 0.7 μm) of flaky silica particles obtainedwithout mixing glycerin with the sol.

It is thought that the decrease in the permittivity of the solventbetween the colloidal particles was caused in a narrow region due toaddition of an aqueous high-permittivity polar organic solvent (organicsolvent a) such as glycerin, as a result of which the thickness of theparticles was reduced. A similar tendency was observed also in the casewhere another aqueous high-permittivity polar organic solvent such asethylene glycol was used instead of glycerin.

Example 7

Colloidal particles were aggregated in the same manner as in No. 3 ofExample 1, and the aggregates were dried at 150° C. to obtain a flakysilica powder (average thickness: about 0.6 μm). The specific surfacearea and the pore distribution of this silica powder were measured bynitrogen adsorption method (BET method). The obtained results were thatthe specific surface area was 149 m²/g, the average pore diameter was 20nm, the pore volume was 0.732 cc/g, and the porosity was about 60%. Thesilica particles constituting the silica powder were so-calledmesoporous bodies having mesopores. It was confirmed that the otherpowders obtained in the above Examples were also composed of mesoporousbodies.

Furthermore, the obtained silica powder was burned with an electricfurnace set at 600° C. for 7 hours. The specific surface area etc. ofthe burned silica powder were measured by BET method. The obtainedresults were that the specific surface area was 111 m²/g, the averagepore diameter was 20 nm, the pore volume was 0.585 cc/g, and theporosity was about 55%. Even after the burning, the silica particlesconstituting the silica powder remained mesoporous bodies having a highporosity.

The mesopores as observed in the above are formed based on the fact thatmetal colloidal particles maintain spaces when the colloidal particlesare aggregated in an organic solvent. If a metal oxide colloid is driedas it is, a highly porous powder having large pores as described abovecannot be obtained.

The average pore diameter etc. of the mesoporous bodies can be adjustedby appropriately selecting a solvent. For example, there is a tendencythat the larger the molecular weight of a solvent is, the greater theaverage pore diameter is. There is also a tendency that the larger thespecific gravity of a metal oxide of a metal oxide colloid used is, thegreater the pore volume is.

Example 8

An amount of 500 g of titania fine particles (“MT-100AQ” manufactured byTayca Corporation) and 42 g of an ammonium polyacrylate surfactant(“HYDROPALAT 5050” manufactured by Cognis Corporation) were added to1125 g of pure water. The mixture was stirred and circulated (stirringspeed: a circumferential speed of 8 m/sec, flow rate: 1 L/min) for 2hours together with 4 kg of zirconia beads of 0.65 mm diameter using ahorizontal continuous wet-type stirred media mill (DYNO-MILL KDL-PILOT Amanufactured by Shinmaru Enterprises Corporation). Thus, a dispersionliquid of the titania fine particles was obtained.

A sol for dropping was prepared by mixing 4.29 g of the dispersionliquid and 10.0 g of an alkaline silica sol (“SILICADOL 30S”manufactured by Nippon Chemical Industrial Co., Ltd.). An amount of 200ml of 2-propanol was put in a beaker. While the 2-propanol was stirredwith a propeller-type stirring rod (rotational speed: 1000 rpm), a totalamount of 51 g of the sol for dropping was added to the 2-propanol bycausing drops of 0.03 g each of the sol to fall from 10 locationsconcurrently. Aggregates were formed by the dropping.

The aggregates were separated from the solvent (2-propanol) bydecantation, dried in a vacuum dryer set at 120° C., and then burned at600° C. for 5 hours to obtain a flaky silica powder A (averagethickness: 0.7 μm, average particle diameter: 4 μm, titania content:about 30% by weight) internally including the titania fine particles(see FIG. 11). Here, the average particle diameter denotes a particlediameter (D50) corresponding to the cumulative volume of 50% in theparticle size distribution measured with a laser diffractiongranulometer (Microtrac HRA manufactured by Nikkiso Co., Ltd.).

The specific surface area and the pore distribution of the titania fineparticle-including silica powder A were measured by nitrogen adsorptionmethod (BET method). The specific surface area was 160 m²/g, the averagepore diameter was 16 nm, the pore volume was 0.550 cc/g, and theporosity was about 55%.

For comparison, a titania fine particle-including silica powder Bobtained by peeling a film from a substrate was fabricated as describedbelow. The above sol for dropping was applied by a bar coater onto astainless steel plate having been previously heat-treated at 250° C. for1 hour, and then was dried at 150° C. A film in which cracks weregenerated by the drying was scraped to obtain a powder. The powder wasburned at 600° C. for 5 hours to obtain the flaky silica powder B(average thickness: 0.8 μm, average particle diameter: 4 μm, titaniacontent: about 30% by weight). The silica powder B was evaluated by BETmethod. The specific surface area was 150 m²/g, the average porediameter was 4 nm, the pore volume was 0.241 cc/g, and the porosity wasabout 35%.

The silica powder A was dispersed in pure water in an amount of 0.33% byweight, and the dispersion liquid was put in a quartz cell having anoptical path length of 0.2 mm. The total transmittances for visiblelight and ultraviolet light were measured with a visible-ultravioletspectrophotometer (UV-3600 manufactured by Shimadzu Corporation). Thetransmittance curve of the silica powder A approximately agreed with atransmittance curve obtained from a 0.1 wt % dispersion liquid oftitania fine particles (“MT-100AQ” manufactured by Tayca Corporation)that was prepared so that the amount of titania was equal to that in thedispersion liquid of the silica powder A (see FIG. 12). It was confirmedthat titania in the titania fine particle-including silica powder Aeffectively shielded against ultraviolet ray. From the transmittancecurve of the silica powder B obtained by the same measurement as above,it was confirmed that the ultraviolet shielding performance of thesilica powder B was inferior to the ultraviolet shielding performance ofthe silica powder A. It is thought that, in the silica powder B, theprojective overlap between the titania fine particles was large becausethe uniformity of distribution of the titania fine particles wasinsufficient.

Example 9

A sol for dropping was prepared by mixing 30% by weight of an aqueousdispersion liquid (fine particle concentration: 30% by weight) of thetitania fine particles described in Example 8 (“MT-100AQ” manufacturedby Tayca Corporation) and 70% by weight of an alkaline silica sol(“SILICADOL 30S” manufactured by Nippon Chemical Industrial Co., Ltd.;silica content in terms of SiO₂ content: 30% by weight). A total amountof 1 g of the sol for dropping was added in drops of 0.01 g each to anorganic solvent (2-propanol) which was being stirred, and aggregateswere thus obtained in the form of a slurry. The aggregates werecollected by volatilizing the organic solvent, and then the aggregateswere pulverized. Subsequently, the pulverized aggregates were burned at600° C. for 7 hours to obtain a silica powder internally includingtitania fine particles. Flaky particles accounted for more than 90% ofthe obtained silica powder.

The above silica powder was observed with a SEM. It was found that thesilica powder was composed of flaky particles having a thickness ofabout 0.7 μm. In addition, the average particle diameter (D50) measuredwith the laser diffraction granulometer described above was 4.0 μm (4.04μm).

The silica powder internally including the titania fine particles wasdispersed in water so that the particle weight concentration (PWC) was0.33% by weight (titania fine particle concentration: 0.1% by weight).The dispersion liquid was put in a cell having an optical path length of2 mm. The transmittance at a wavelength of 300 nm was 0.2%, as measuredwith a spectrophotometer. In addition, a dispersion liquid was preparedby mixing the silica powder with water so that the PWC was 0.1% byweight (titania fine particle concentration: 0.03% by weight). Thetransmittance of the dispersion liquid at a wavelength of 300 nm was14.7%.

Furthermore, silica powders internally including titania fine particlesat various concentrations were fabricated. Each of the obtained silicapowders was dispersed in water so that the titania fine particleconcentration was 0.1% by weight, and the transmittance at a wavelengthof 300 nm was measured in the same manner as above. In addition, each ofthe obtained silica powders was dispersed in water so that the particleweight concentration (PWC) was 0.1% by weight, and the transmittance ata wavelength of 300 nm was measured in the same manner as above. Theresults are shown in Table 21. When a sol for dropping containingtitania fine particles at a concentration of 60% by weight or more wasused, no aggregate was obtained.

TABLE 21 Transmittance at wave- Titania fine length of 300 nm (%)Average Proportion particle content Titania fine particle of flaky inparticles particles PWC diameter particles No (% by weight) 0.1% 0.1%D50 (μm) (%) 211 10 0.0 34.7 6.97 >90 212 20 0.1 22.2 6.65 >90 213 250.1 18.4 4.41 >90 214 30 0.2 14.7 4.04 >90 215 35 0.4 14.2 3.60 ≃80 21640 1.2 16.3 4.10 ≃50 217 50 8.5 27.7 4.58  ≃0

FIG. 13 shows the light transmittances at a wavelength of 300 nm of thedispersion liquids in which the PWC was 0.1% by weight. In the rangewhere the content of the titania fine particles in the silica particlesis 35% by weight or less, as the content of the titania fine particlesincreases, the transmittance decreases due to the ultraviolet shieldingeffect of the titania fine particles. However, in the range where thecontent of the titania fine particles is more than 35% by weight, thetransmittance increases despite increase in the amount of the titaniafine particles. This means that the probability of the titania fineparticles being present in the flaky particles at such positions as tooverlap each other was increased, and the proportion of titania fineparticles that contribute to light absorption was accordingly reduced.In view of this fact, the proportion of ultraviolet-absorbing particlesadded to metal oxide particles is preferably 20% by weight to 45% byweight, more preferably 25% by weight to 40% by weight, and particularlypreferably 27% by weight to 38% by weight.

However, the higher the proportion of the titania fine particles in thesol to be dropped is, the lower the proportion of particles obtained inthe form of flakes is. In the case where particles should be obtained inthe form of flakes, the proportion of ultraviolet-absorbing particlesadded to metal oxide particles is preferably 35% by weight or less, andparticularly preferably 30% by weight or less.

Example 10

An amount of 4.67 g of an alkaline silica sol (“SILICADOL 30S”manufactured by Nippon Chemical Industrial Co., Ltd., and containing 30%by weight of silica in terms of SiO₂ content) and 2.40 g of an aqueousdispersion of carbon black (“WD-CB2” manufactured by Daito Kasei KogyoCo., Ltd., and containing 25% by weight of carbon black) were mixed toobtain a dropping liquid 1 in which the weight ratio between carbonblack and silica (in terms of SiO₂ content) was 30:70.

An amount of 3.33 g of an alkaline silica sol (“SILICADOL 30S”manufactured by Nippon Chemical Industrial Co., Ltd., and containing 30%by weight of silica in terms of SiO₂ content) and 4.00 g of an aqueousdispersion of carbon black (“WD-CB2” manufactured by Daito Kasei KogyoCo., Ltd., and containing 25% by weight of carbon black) were mixed toobtain a dropping liquid 2 in which the weight ratio between carbonblack and silica (in terms of SiO₂ content) was 50:50.

An amount of 20 ml of each of the organic solvents listed in Table 22was put in a glass bottle, and a total amount of 0.5 g of the droppingliquid 1 or 2 was added in drops of 0.01 g each to the organic solventwhile the organic solvent was stirred with a magnetic stirrer(rotational speed: 800 rpm).

Aggregates formed by the dropping were suction-filtered, washed with2-propanol, and then dried by a dryer set at 150° C., to obtain a silicapowder internally including carbon black fine particles. The shapes ofthe obtained particles were observed with an optical microscope. Theresults are shown in Table 22.

TABLE 22 Dropping Shape of No Organic solvent liquid particles 2212-propanol Dropping Flakes liquid 1 222 2-propanol 60% by weightDropping Fibers 2-ethyl-1-hexanol 40% by weight liquid 1 223 2-propanolDropping Flakes liquid 2 224 2-propanol 60% by weight Dropping Thickfibers 2-ethyl-1-hexanol 40% by weight liquid 2 An observation result ofthe powder obtained from No. 223 is shown in FIG. 14, and an observationresult of the powder obtained from No. 224 is shown in FIG. 15.

Example 11

A sol for dropping was obtained by mixing an alkaline silica sol whosemajor cation is ammonium ion (“SNOWTEX-N” manufactured by NissanChemical Industries, Ltd.) and a tin oxide sol (“Ceramace S-8”manufactured by Taki Chemical Co., Ltd.; tin oxide content in terms ofSnO₂ content: 8%) so that the weight ratio between SiO₂ and SnO₂ was2:1. A powder containing silica and tin oxide was obtained in the samemanner as in Example 1 except that the sol for dropping was used. Itshould be noted that the organic solvent used was 2-propanol. The amountof the obtained powder was about 0.1 g.

For comparison, a powder was obtained in the same manner as above exceptthat the entire amount of the sol for dropping was substituted by theabove alkaline silica sol “SNOWTEX-N”. The amount of the obtained powderwas 0.001 g.

Example 12

An amount of 50 ml of each of the organic solvents listed in Table 23was put in a beaker. A total amount of 1 g of an alkaline silica solwhose major cation is ammonium ion (“SNOWTEX-N” manufactured by NissanChemical Industries, Ltd.) was added in drops of 0.01 g each to theorganic solvent. During the dropping of the alkaline silica sol, theorganic solvent was stirred with a magnetic stirrer (rotational speed:800 rpm). Through this operation, it was visually observed that thecolloidal particles were aggregated to form a slurry in the organicsolvent.

Next, the aggregates of the colloidal particles were separated bysuction filtration from the solvent in which the colloidal particles hadbeen aggregated to form a slurry. The obtained aggregates of thecolloidal particles were dried in a vacuum dryer set at 150° C., toobtain a silica powder (an assemblage of flaky silica particles).Finally, the dried silica powder was burned at 700° C. for 5 hours. Theweight of the obtained powder was about 0.19 g for each of the organicsolvents. Ammonium ion in each organic solvent is thought to havefacilitated aggregation of the metal oxide colloidal particles,considering that the weight of a powder obtained by using an organicsolvent containing no ammonium ion is about 0.001 g, which is extremelysmall. In addition, the sodium concentration in the silica powder wasabout 0.1% by weight in terms of oxide content (in terms of Na₂Ocontent), as measured by chemical analysis.

For comparison, a silica powder (an assemblage of flaky silicaparticles) was obtained in the same manner as above, except that“SILICADOL 30” (manufactured by Nippon Chemical Industrial Co., Ltd.),which is a metal oxide sol whose major cation is sodium ion, was usedinstead of “SNOWTEX-N”, and that 2-propanol was used as the organicsolvent. The sodium concentration in the silica powder was about 1.6% byweight in terms of oxide content (in terms of Na₂O content), as measuredby chemical analysis.

TABLE 23 Organic solvent Blending Blending Ammonia amount of amount ofconcentra- 2-propanol ammonia tion (% by No (g) Ammonia source source(g) weight) 221 49.85 Concentrated aqueous 0.15 0.084 ammonia 222 49.5Concentrated aqueous 0.5 0.28 ammonia 223 45 Concentrated aqueous 5 2.8ammonia 224 49.5 Ammonium acetate 0.5 0.29 225 49.95 Ammonium acetate0.05 0.029 226 42.5 Ammonium benzoate A 7.5 0.21 227 47.5 Ammoniumbenzoate A 2.5 0.070 228 46 Ammonium benzoate B 4 0.022 Theconcentration of the concentrated aqueous ammonia is 28%. The ammoniumbenzoate A is an aqueous solution having a concentration of 11.43%, andB is an aqueous solution having a concentration of 2.29%.

1. A mesoporous particle having a flaky shape, having a single-layerstructure, having a thickness of 0.1 μm to 3 μm, and having an averagepore diameter of 10 nm or more.
 2. The mesoporous particle according toclaim 1, comprising metal oxide particles aggregated in such a manner asto form mesopores between the particles.
 3. The mesoporous particleaccording to claim 1, having a specific surface area of 50 m²/g to 500m²/g.
 4. The mesoporous particle according to claim 1, comprisingaggregated particles of at least one metal oxide selected from siliconoxide, titanium oxide, zirconium oxide, aluminum oxide, tantalum oxide,niobium oxide, cerium oxide, and tin oxide.
 5. The mesoporous particleaccording to claim 1, internally including a functional materialfunctioning as at least one selected from a water repellent agent, anantibacterial agent, an ultraviolet absorber, an infrared absorber, acoloring agent, an electric conductor, a heat conductor, a fluorescentmaterial, and a catalyst.
 6. The mesoporous particle according to claim5, wherein the functional material is titanium oxide.
 7. The mesoporousparticle according to claim 6, containing the titanium oxide in anamount of 20% by weight to 45% by weight.
 8. The mesoporous particleaccording to claim 1, having a sodium concentration of 0.001% by weightto 0.7% by weight in terms of Na₂O content.
 9. The mesoporous particleaccording to claim 1, wherein the thickness is 0.7 μm or less.
 10. Themesoporous particle according to claim 9, wherein the thickness is 0.4μm or less.
 11. The mesoporous particle according to claim 1, having apore volume of 0.17 cc/g or more.
 12. The mesoporous particle accordingto claim 11, wherein the pore volume is 0.5 cc/g or more.
 13. Themesoporous particle according to claim 12, wherein the pore volume is0.7 cc/g or less.
 14. The mesoporous particle according to claim 1,wherein the average pore diameter is 30 nm or less.
 15. A method forproducing the mesoporous particle according to claim 1, the methodcomprising the steps of: feeding a metal oxide sol having a pH of 7 orhigher and containing metal oxide colloidal particles as dispersoids andwater as a dispersion medium, into a liquid containing a water-misciblesolvent that is a protic solvent having a relative permittivity of 30 orlower at 20° C., or that is an aprotic solvent having a relativepermittivity of 40 or lower at 20° C., and thereby forming a flakyaggregate of the metal oxide colloidal particles in the liquid; andsubjecting the flaky aggregate to at least one treatment selected fromdrying, heating, and pressurization, to increase a binding force betweenthe metal oxide colloidal particles constituting the flaky aggregate,and thereby converting the flaky aggregate into a flaky particle that isinsoluble in water.